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 visually guides through the process of replacing aircraft battery cables, including those connected to the starter and master solenoids, and notes the replacement of an undersized starter cable.
It emphasizes the critical importance of careful cable routing, securing, and inspecting for corrosion at various points from the engine to the rear battery box.
The battery cable replacement provides opportunities to perform additional maintenance, such as removing unnecessary power taps and fixing loose connections.
Proper tools, like a heavy-duty crimping tool, are essential for the job, and thorough photographic documentation of the work is highly recommended.

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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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