Positive Battery Cable Extension

Ok, I replaced the engine ground connector with a new copper 2ga lug. It struggled a little on the first try but then confidently started 3 times in a row. It seemed so minor but looks like it made a big difference. So, lesson learned: use the correct connector sizes!

 

Going by this it sounds like the solenoid is sticking. If something was wired wrong it would never start.

 

I realize this thread is a year old but I'm facing the same dilemma. Am installing a dual battery setup with one battery on the passenger side and one in the OEM position. Will be using Mil-Spec battery terminal connectors. The connector Toyota used to connect the starter motor wire to the battery positive post will not work with my setup. Need to lengthen the starter positive cable and add a ring terminal on the end. I'm going to cut off the existing Toyota terminal and use a Blackburn copper crimping type butt splice, P/N CSP2 to attach a short cable extension. I bought a crimper on EBAY called a 10 ton crimper. Cost $25. A zillion folks sell the same thing---made in China. It will make the 6 sided crimp I need and will also crimp the battery lug ring terminal I'll need on the battery end. The kit has dies for 9 different size lugs that it will crimp. I plan on using 2AWG welding cable for the extension. Best I can tell the positive cable is 2AWG. I'll double heat shrink the butt splice. I could just run a new cable to the starter but it looks like a nightmare to fish that thing out and fish a new one in. Plus, the starter end appears to have some kind of wierd plastic housing over it. Would like to avoid messing with that stuff. I will probably have to install a new ring terminal on the end of the negative cable. Have not looked at that yet except that I think that wire size is 4 AWG. Except for the welding wire looks like I'll have to order the butt splice and lugs via internet. Hard to find anything locally.