When we
brought the rig back to our garage, it was time to take out
the stock battery and tray, which is very quick, only about
5-10 minutes to remove.
Disconnect the battery. Remove the battery cables, battery
hold down and remove the battery.
Depending upon your TJ, you may have to remove the PDC
(Power Distribution Center) from its mount and move slightly
forward, which we had to do but we did not have to remount,
we simply removed it until the new tray and dual batteries
were in place and then remounted to original position.
If you own a Rubicon, you may have enough room to skip this
step. You may also want to move the PCM upward if you
need more room. You can relocate the PCM higher by simply
re-drilling the 3 holes used to mount the unit, we did not
have to perform this step either.
Unbolt
the factory battery tray and remove the battery sensor.
Install
the battery sensor into the new tray and install tray using
the hardware provided. Be sure you don't pinch the sensor
wires.
Install
the first battery and slide it to the end of the tray
closest to the engine.
Test fit
the first battery and check clearances to the wiring harness
going to the PCM (Powertrain Control Module) and the two
studs used to mount the AC Accumulator. If the studs touch
the battery, trim both studs approx. 3/16" to clear. If the
wiring harness needs to be moved, disconnect both the black
and white connectors from the PCM and route the wires above
the heater hoses.
Reinstall the first battery and face the side posts towards
the engine. Install the second battery facing the same
direction. Install the batteries by standing the battery on
its end, then position it in place. **'97-'02 TJ's have a
fan motor that protrudes through the firewall just under the
PCM. You may need to trim the fins on the back of the fan
just slightly to help clear the second battery. Install the
second battery and check this clearance. You can trim the
fin by using wire cutters and clipping off the fin.
Install
the new battery hold down using the long bolt and washer
provided. Snug the bolt hand tight only. Do not over
tighten!
Install
the PDC back into its mount.
Since we had a winch installed, it was just a matter of
length of the your wires and connect to easiest /closest
position with out interference of other wires. We
chose to use 2/0 Gauge wire to connect each battery.
This was a simple process; we purchased a 24" 2/0 Gauge
battery cable, and a set of new battery cable lugs.
Cut the battery cable to desired length, usually will be
anywhere around 7"-10", depending upon your choice of setup.
We cut the cable to desired length, stripped off about a
1/2" to install new lugs. We crimped the lug onto the
cable and wrapped with electrical tape.
We reinstalled the stock battery cables, new cables we
made and winch lines, and that was it. Since the
install we went for a full day of winching, not only rigs
out of mud pits, but also pulled up bushes and small tress
that needed to be done for family and neighbors and had no
problems.
Nest on
the list is a Mean Green Alternator to make sure these New
Optima Batteries stay fully charged.
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