Photo Gallery: Replacing Your Battery Cables

A step-by-step look at replacing aircraft battery cables

Tuesday, October 31, 2017 at 08:11 AM ET

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Key Takeaways:

The article illustrates the step-by-step process of replacing battery cables in an aircraft, showcasing various components like the engine, starter solenoid, and master solenoid.
It highlights the importance of proper cable routing throughout the cockpit and fuselage, recommending inspections for corrosion along the way.
The process involves using specialized tools, such as a heavy-duty crimping tool, for secure connections.
During the replacement, additional maintenance opportunities arose, leading to the discovery and correction of issues like loose connections and unnecessary power taps.

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Starter solenoid with new battery cable — Starter solenoid with new battery cable. Not shown is the new cable from the starter solenoid to the starter that I built to replace the smaller diameter copper cable that had been installed previously. Since I had the extra cable and terminals I made a new cable. Also shown is the aluminum cables that feed the instrument buss. They were not replaced and are not called out for replacement in the service bulletin.

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