Guys, I really hate to show such ignorance but I have a battery problem. I have the negative battery cable on the driver's side off, disconnected from the battery. The bolt going through the clamp that tightens it is broken, no ends. How do I change that bolt with simple hand tools? I can't get a wrench or even pliers on the bolt to move it. Both ends are flush with the cable clamp.

 

1. You could try using a hammer and a punch to knock it out.

2. If corrosion is an issue, mix up some baking soda and water and use this to remove it.

Maybe others will come up with different ideas. Good luck!

 

Screwdriver and a wrench pound it out.

 

another vote to punch it out . . .

 

Large flat blade screwdriver used to spread terminal and then pliers to twist exposed bolt of punch and drive out.

 

Thanks for all the suggestions guys. I tried pounding it out, and spreading the terminals to expose the bolt... couldn't get it. I put it back on with dielectric grease, clamped it with a small C-clamp for now. I don't have the time to fix it right. I will get to it the first weekend in October when I have a day to get into it. I'll take the whole cable off, put it in a vice and drill it. Another 15 minute job that takes all day! Twice in one week I have had stuff go on the truck, not bad for 130,000 miles though.

 

why not take five minutes and clamp a new end on the cable?

 

yep, just buy a new heavy duty battery connector for $5 or so. Cut the old one off and install the new one. You can get them at any parts store, autozone, advance, o'reilis or whatever you have. I think Walmart even has them.

 

This is what I would do:
I really don't trust those clamp on repair cable ends with 2 bolts especially with the high amount of current required to start a diesel engine.

Since I have all of the crimpers I would simply replace the end with a cast brass one but if I were you I would go to your local welding supply and get some copper lugs appropriately sized for your cable.

Clean up the cable and either solder on or crimp on the new lug, apply some adhesive lined heat shrink tubing and connect it to the battery using some military style battery terminals that will now simply bolt on.

You can get these terminals from Napa.

Negative.
http://www.napaonline.com/NOLPPSE/(S...618_0218264716

Positive.
http://www.napaonline.com/NOLPPSE/(S...223_0063685508

See what else they have, and you thought battery terminals only came 2 ways, clean or corroded.
http://www.napaonline.com/NOLPPSE/(S...=0&Ntk=Keyword


But this is just what I would do.
Jim