Non-winch to Winch Bumper Project cont.
Back to Introduction: Winch-Mount versus Non-Winch Bumpers
Back to Part 1 - Bumper Modification
Back to Part 2 - Mounting the Winch
Back to Part 3 - Relocating the Solenoid Box
Back to Part 4 - In-Cab Winch Control
Part 5 - Electrical Upgrades (you are here)


Part 5 - Electrical Upgrades

Adding a winch has caused me to think about the battery and whether or not it is up to the task. The last thing I want is to be miles from pavement and need to use the winch and then have the battery die on me. My battery is the original one that came with the Jeep so that means it is over 7 years old. On top of that I believe its on its way out anyway because I can no longer see the battery test indicator light.

Ideally a dual battery setup would be best, but I know I don't have any more room inside the engine compartment, and I'm not realy wanting to carry a heavy battery in the rear cargo area. So I needed a quality battery that was also a "deep cycle" battery that can handle the huge power demands of a winch. A regular battery might be able to provide enough power but its the ability to recover thats the problem. After doing some research I chose an Optima BlueTop D34M deep cycle battery. Optima batteries are extremely popular and you've probably seen the Red and YellowTop batteries they have also. Here's why I picked the BlueTop D34M:

RedTop - starter battery only
YellowTop - dual purpose (starting and deep cycle) It has auxilliary side posts, as does the RedTop also. The side terminal accepts a 3/8"-16 screw. YellowTop has a 12 month free replacement / +12 month prorated warranty.
BlueTop - built for marine applications. They have a starter only version (34M) and a dual purpose (starting and deep cycle - D34M) so be carefull if you order that you get the deep cycle. Performance wise its technical specs are identical to the YellowTop however instead of side posts it has two auxilliary posts on top of the battery. The warranty is better however, as it is 18 month free replacement / +18 month prorated.

Auxilliary posts, either on the side or on top, should not be used for starting or heavy loads (like a winch). However they are perfect for auxilliary stuff like lighting, CBs, etc. Maximum load should be kept to 75-100A to be safe.

Along with the new battery, I decided to upgrade my battery cables also so I ordered a set of HD cables from Kelly's Works In Progress


Jon Kelley goes by "5-90" on NAXJA and he's very knowlegable ( he's the author of The Jeep I6 Power Manual) and has great customer service as well. But honestly, that's not why I decided to get his cables instead of going with a different company that offers a similar product. I went with Works In Progress simply because they are heavier gauge (1AWG welding cable vs 2AWG), they are more complete (I got 5 cables instead of just 4), and they even cost less also! On the Works In Progress website, Jon has the kits broken down very well by year with clear instructions so you know you are getting the right cables for your XJ. I should also add that he can make any custom cables you want so don't feel limitted to order from just what you see on his site. He can easily provide cables for a dual-battery setup, or secondary distribution for stereos and lights, and this can be for any vehicle, not just Cherokees.

Here are the HD battery cables next to my stock ones. The size difference is quite remarkable. As I mentioned above, these HD cables are 1AWG and the stock cables should be 8AWG. Jon tells me that if yours is a 1990 and earlier, AMC specified the use of 6AWG. Either way, it almost seems like the stock ones would be innadequate even for OEM applications; and these HD ones might even be a tad overkill. I like that though!


Because I would need a new set of terminals, I got these brass ones from Works In Progress also. I appreciate the explanations on his site about why brass is a better conductor than lead.


After installing the HD battery cables, I was ready to add in the Optima. The Optima is also slightly smaller than the stock battery was but it still fits in the stock battery tray and uses the battery hold-downs just fine. You'll also notice that I have the power leads from the winch connected to the main terminals and have some smaller wires that power my other junk attached to the aux. post (positive).


Here's a final photo of everything I installed under the hood for this project.


When I fired up the engine for the first time with the new battery and cables, it literally started on the first crank! I could definitely notice the improvement. It should be interesting to see the difference next winter because my stock battery used to really seem weak when starting in cold weather.


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