Repairing battery clamps

This is the Forum for all your Citroen Technical Questions, Problems or Advice.

Moderator: RichardW

User avatar
(Donor 2020)
Posts: 125
Joined: 20 Mar 2005, 19:17
x 63

Repairing battery clamps

Post by CitroenCrazy »

I've just changed this loom on my recently acquired Xantia because part of the battery clamp has been damaged. It's the bit from the positive terminal on the battery to the alternator, starter motor and underbonnet fuses.
They seem prone to this type of failure. On the previous Xantia I bought, both terminals had been broken. Fortunately, I had spares to to replace them properly, but now I have none left
Battery tray 01.JPG
In theory, the lead could be melted off the end and a new terminal cast in place. I just wondered, has anyone has ever enccountered a way of repairing something like this that retains the OEM look ?
User avatar
A very naughty boy
Posts: 49658
Joined: 30 Apr 2005, 23:33
x 6204

Re: Repairing battery clamps

Post by CitroJim »

Casting a new one should be very possible...

It should be possible to sand cast one if you have a decent example as a template...

I always used to cast my own lead sea fishing weights when I was a youngster...

Maybe plain lead will not be hard enough... It may need to be a lead alloy...

Runner, cyclist, time triallist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
User avatar
white exec
Moderating Team
Posts: 7445
Joined: 21 Dec 2015, 13:46
x 1752

Re: Repairing battery clamps

Post by white exec »

The original lead clamps are crimped on to the cable strands, and do lose their grip over time. They're not air-tight, and the strands also oxidise (blacken), and a resistance builds up. Symptom is poor starting, and the clamps getting warm/hot when cranking.

Personally, I'd go for bolt-down brass clamps as replacements. Always possible to paint them grey (or anodize?) for an OE look.
Steve Walsh
Donor 2024
Posts: 466
Joined: 25 Oct 2019, 07:20
x 364

Re: Repairing battery clamps

Post by Steve Walsh »

I have always used these. Top quality ... ccessories
Thanx to Marc and all the admins & knowledgeable people that make this the best forum on the interweb. =D> =D> =D>