1991 Volkswagen Vanagon Battery Cable Battery Terminal End Service Cost

Batteries are storage units for electricity, and battery cables transmit that electricity to components that require battery power to operate. The link that ties these two vital components together is known as a battery terminal. As the term 'terminal' implies, battery terminals are located on the ends of the battery cables. They are crimped onto the thick cables, and attach with a bolt directly onto the battery posts. The battery terminals are snugly fit onto the battery post, or bolted into the side of the battery to provide a clean, secure attachment and an excellent electrical connection.

Made of some sort of pliable metal, the battery terminals transmit electrical power from the battery to the battery cables. As stated above, they are tightened to provide a secure connection, and the metal used will be sufficient for conducting the high amperage of the battery for charging and discharging energy.

A battery terminal failure is typically indicated by a complete loss of electrical power to the vehicle, engine stalling, intermittent function of all electrical components, or very low voltage from a charged battery. Often times the terminals will look powdered and corroded, or there may be a crack on the loop that attaches to the battery. If the terminal is separated from the battery cables or loose, that is also an indication there is a problem with the terminal or battery cable.

If the vehicle operates normally, but the battery cables look corroded, the battery terminals, battery, and battery posts should be cleaned and inspected. The likelihood of failure increases the longer the battery cables are corroded, so cleaning should be performed as early as possible. If the vehicle is unable to start, run, or operate electrical functions due to a broken or corroded battery terminal, the terminal will need to be cleaned or replaced immediately to restore functionality.

Battery terminals are subject to gas discharge from leaky batteries, and batteries tend to last three to four years. Depending on the age of the battery, the battery terminals will corrode at different rates, but the health of the entire starting and charging system weighs heavily on the condition of the battery terminals. A vehicle kept in good maintenance may never need the battery terminals replaced, but lack of maintenance and severe operating conditions for the starting and charging system will cause the replacement interval to become shorter than normal.

When diagnosing a vehicle that suffers from a loss of battery power, the terminals will be visibly inspected, cleaned if necessary, and the battery will be charged. If the charged battery combined with the cleaned terminals will not provide sufficient electrical power to the vehicle, a technician will conduct a starting and charging test. If the test results show a reduction in power between the battery and battery cables, the terminals, and likely the battery cables, will be replaced.

There are two types of replacement battery terminals. The original-type cables will have an integrated battery terminal either bonded or pressed to the battery cable, while most aftermarket battery terminals are designed to receive the end of the existing battery cable. If aftermarket battery terminals are used, the old terminal will be cut off, and the battery cable will be tightened or crimped into the replacement. However, if original type parts are used, the battery cables will be replaced by disconnecting both ends of each battery cable.

It is recommended to replace the cable with the terminal, as terminals that allow the existing battery cable to fasten to the new terminal are less reliable, require more maintenance, and are typically not as sturdy as factory terminals. Also, if the corrosion is severe, the battery cable could offer too much resistance to the battery, causing a failure to start the engine when the battery is only slightly drained.

When cleaning corrosion from or replacing battery terminals, it is imperative that the battery be disconnected before attempting this repair. The risk of electrical shock is high, and the risk of vehicle damaging battery arching is highly possible when the battery is being serviced. Due to the acidic nature of battery corrosion, rubber gloves should be worn before contacting the powder-like corrosion on the battery. Never cut a live battery cable, even with rubber handled cutting tools. This may cause electric shock.

Cleaning or replacing battery terminals, even when the battery cables must be replaced is a fairly easy task. It does require basic tools and a solvent, but these objects are typical household items. When the battery cable must be replaced, it is much easier to replace one at a time, so the locations and fasteners are not confused.