Just bought my Optima Yellow Top battery for my Y2K 4Runner and when I did the test fit yesterday I found the main battery leads to the fuse block and the ground leads do not reach the top posts properly. After looking at some options I though about getting longer cables (aftermarket) or re-routing the factory ones. The winch battery and ground cables are not an issue as they have plenty of slack. It is just I do not want to change out the factory battery and ground cables only to create issues with possibly getting inferior aftermarket cables or creating issues with the ground points. I am going to be installing a battery disconnect for the winch positive lead so it can be energized only when wheeling. If in an accident there will be no potential of the winch battery lead shorting to ground since it is in the bumper and stands a higher chance of getting smashed during a frontal collision. I am using a McMaster-Carr battery switch part #69685K79 which I have on order. It is the same battery switch as used in firetrucks and such and has plenty of current capacity for my application. It is actually a dual-battery manual switch but I will only be using one of the inputs at this time.

Since the Optima has top post and side terminal mounting I thought about hooking up the winch to the top posts and coverting the factory cables to side post mounts. The Optima doc says to use the side posts for vehicle starting only and to use the top posts for both vehicle starting and heavy accessories such as audio systems, lights, etc. But is says nothing about using both the side terminals and top posts at the same time. I don't see it being a problem as they both look bridged to the same bus. Has anyone else done this and how did you approach it. My search did not turn up what I was looking for. I found dual-battery stuff but I am not at that point yet but I will be doing that later down the road.

Thanks for the input in advance.

Ricochet

I have the red top and have been using both terminal for a long time. One for the truck, the other for ExtremeAir air compressor.

I just put a Yellow top in my 1999 4Runner. you can see a picture of it here: http://67.122.16.97/bbs/index.php?board=1;action=display;threadid=220;start=15

To get the white wire out of the fusebox to reach I simply re-routed it, by drilling a hole in the side of the fusebox. There are 4 tabs that you can depress to pull the fuseblock out. Then I rebent the battery holddown bracket and lengthen the ground wire that attaches to the body. The rest of the wires were long enough. I'll be attaching my wench cables to the side post when my bumper arrives.

It's easy to mount with a short positive extension and a 1" spacer underneath. I have my winch and main battery connection attached directly to the posts and don't even mess with the side posts. Do a search for 'optima' here and yotatech for a lot of discussion on this topic.

I appreciate the input. I looked at the wire from the fusebox and thought the same thing about re-routing it but it was getting late and I did not want to rip things apart in the dark and have a time getting things back together and royally mess things up. And the short chassis ground was the ground lead I was refering to. I just wanted to make sure noone else had any issues with ground points if you had to change them to make things work. I was also concerned about one of the battery leads being a fusable link. If so I did not want to mess with that a sit would cause major issues down the road if I had an internal short from my harness to the battery.

I think the re-route through the fuse housing is the way I will go. I was kind of looking to plan the wiring to accomodate a dual battery setup as well when I get to that later on, so I need to see where it will go under-hood. I figured a little planning now will same me a lot of time later when I get to the dual battery setup. The alternator is next after looking in the tech archives. May need a little more juice when all is said and done.

Thanks again guys for the input. I'll let you know how it turns out. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Ricochet

The fuse box route is a slick way to go.

I know there are a lot of folks who would love to see dual batteries under the hood. I bet you could sell a few mounting brackets if you can make it work. Good luck! <img src="/forums/images/graemlins/kewl.gif" alt="" />

When I first put the battery in, I just made a wood spacer block, to fit on top and stretched the cables to fit, then left the chassis ground wire loose. My brother's car battery died, so instead of him buying a new one, I gave him my old battery. I too was working in the dark when I first put the battery in. Once I had some time, I made all the mods to fit the battery more cleanly. My vise's jaws were just the right width to fit my battery bracket, so re-bending it was easy. I didn't put a spacer underneath, because I wanted to keep the terminals as far away from the hood as possible, plus it makes the red cable too short to fit. I also ground off the 2 locator pins on the stock battery tray.

Before trying to pull the fuseblock out, unbolt the other white wire on top, then you can pull the block up easily, it's a good time to do the foglight mod while it's apart.

Going to try and get it fit in this afternoon. It got down to 28deg. this morning and it was really slow turning over. The old battery is getting close to giving up the ghost. Not bad for a three year old factory battery. But those factory Panasonic batteries are pretty tuff.

Anyhow, I hope to find a good spot or arrangement for mounting a dual-battery under-hood. One that is not only easily accessible but also rock-solid reliable. Nothing worse than a battery coming loose while your wheeling to mess up the whole day. It is kinda cool when they arc to the underside of the hood ... that is until they blow! <img src="/forums/images/graemlins/drunk.gif" alt="" />

More to follow. Thanks to everyone for the help.

Ricochet

Do NOT use the side posts on an Optima for a winch or other very-high-amperage draw device (a winch is all I have of such a thing...). You will possibly melt the inner strap in the battery and wonder why the top posts are live and the sides are dead.