Kinda an odd problem about my 12V battery-cables

Discussion in 'Gen 2 Prius Main Forum' started by priuslyfe, Feb 1, 2026 at 12:48 PM.

  1. priuslyfe

    priuslyfe Member

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    thanks for the advice. HAD to walk through snow and ice today and thought maybe a better design is 1) battery was moved towards the front of the car ie. the normal place or 2) have a hot air vent from the engine towards the battery to at least mitigate the risk of freezing.

    also discovered that while walking through snow and ice, you often take twisted ankle steps, sometimes several in a row. a technique that seemed to work for me today is trying to use one foot as my flat foot and the other as my twist-foot, thus giving me some stability. I seemed to move marginally faster.

    the reason I don't use both as my flat-foot is that isnt a reasonable request. the reason for this is most people havent shoveled their sidewalks. i dont fault them as snowplows have covered them with 2ft of snow that has since become blocks of ice.
     
  2. Hayslayer

    Hayslayer Active Member

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    The other end of that heavy cable is connected as the supply source for the underhood fuse box in the upper driverside of the engine compartment. There is no real slack to be had.
    You'll either need to get the crimp fitting removed, opened up and recrimped/soldered, OR do what some others have done and find a salvage yard that has a gen 2, cut that cable several inches back and crimp/splice the new piece of 'yard' cable onto yours. You don't want to make a loop in the wire, so you'll need to trim it as needed to get the correct original length. Otherwise it's just a pain to stuff it in place.
     
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  3. ChapmanF

    ChapmanF Senior Member

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    but, for that size wire and ampacity, is less common, and requires the heavy crimp tools they have at your neighborhood independent auto electric shoppe.

    I would probably try to get the last foot or so of that wire out of a salvage car, then take it to my neighborhood auto electric shoppe and have them make it up. They'd charge me less than the cost of a heavy-nice-person tool I might never use again.
     
  4. priuslyfe

    priuslyfe Member

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    update:

    half accomplished. got about 6" off that cable which is firmly into the connector off a salvage car. much more length is hard to get as this cable becomes intertwined with others (the main?) that make pulling out more length to cut unfeasible. there is very little slack available at all at most 2-3 inches anyways. the cable basically makes a straight shot to the positive terminal with no room for modifications in length.

    think I'm gonna go with my idea of jamming the wires together. once you cut the cable you see there are about a dozen heavy duty steel wiress housed within the cable. i'm gonna need a breakaway to prevent this from happening again. ideally toyota should have had a white connector about a foot back that I could detach (however i guess ideally i should be living in a warmer place. always forget about this snow/ice in the middle of summer).

    too cold to finish this job today and light is starting to wane so yeah **** that.
     
    #24 priuslyfe, Feb 2, 2026 at 4:51 PM
    Last edited: Feb 2, 2026 at 4:57 PM
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  5. rjparker

    rjparker Tu Humilde Sirviente

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    If it goes to Ready with the short salvage battery wire jammed into the remaining vehicle harness it might work for a short time. A battery that could not staying charged before has no chance with a battery cable rigged in that manner.

    To properly repair using a salvage pigtail (piece) it should be crimped or lugged at the spliced connection.

    Crimp sleeve for wires (sized for wire diameter - typically 4-6 awg with automotive stranded)
    IMG_0410.jpeg


    Lug Butt Splice (tighten with allen wrench and insulate)
    IMG_0415.jpeg


    Amazon Butt Splices
    IMG_0408.jpeg IMG_0407.jpeg


    Once you splice the wires together, you still need to do something about your battery. It is likely weak and needs testing and replacement as indicated.

    Again, a good battery adequately charged won't freeze. How many of your neighbors are removing their battery every night? Some will attach a battery maintainer as I have when in Calgary during the winter. Many do nothing and still crank their high amp starters.

    A Prius 12v battery does not have to supply large currents and is in the cabin rather than under the hood. After achieving Ready, a weak battery can initially charge by drawing 60-80a from the hybrid system. A loose, "jammed" connection won't do it and is likely to fall out and short the battery. At best you can be stranded somewhere.
     
    #25 rjparker, Feb 2, 2026 at 11:35 PM
    Last edited: Feb 3, 2026 at 12:57 AM
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  6. ChapmanF

    ChapmanF Senior Member

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    The markings on that splice identify the not one but two distinct special tools and dies to be used to properly crimp it onto the wire.

    Your neighborhood independent auto electric shoppe already has the right tools and dies to do that, and when they're done you'll have a properly all-around-crimped and insulated connection, more reliable than the set-screw butt connectors, and they'll probably be done in a couple minutes and you'll be on your way for a nominal charge.
     
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