Ultimate Guide on How to Replace a Melted Battery Terminal

Have you ever wondered why your car battery is not functioning correctly? Many of us know the reason behind this particular issue, and many find it out when they open their car’s engine trunk. 

There are several ways to replace melted battery terminals, which are more cost-efficient than replacing a whole new battery. It is effortless, and by following some methods, anyone can do it alone.

A surprising fact about replacing the terminal is that it is effortless, and you can even perform the replacement after reading this article to the end and follow the instructions below.

How To Replace Melted Battery Terminal

What Causes Battery Terminal To Melt?

Melting can happen based on many factors, like overheating the battery or cable management.

Sometimes it happens because of the rough surface of the terminal material (Lead) that causes a spark and generates heat.

Too Much Heat and Cable Management (Both Terminals)

Most batteries are made out of Lead material. But lead is not easy to melt. It requires 327.5C heat to start melting. This kind of heat occurs because of wrong cable management.

Loose or Over Tightening Connections (Negative Terminal)

It might be the most common reason, and it can be on both negative and positive terminal.

When the connector has a gap, the cable terminal creates an arc, and due to that arc, the battery will get hot while passing electricity.

And thus, the terminal will start melting. Over-tightening can also cause the same problem.

An Old and frayed connector ends ( Both Battery Terminal)

Connectors (broken) can also be blamed for heat because these faulty connectors make electrical shorts to the ground and damage the battery, which eventually leads to the melting of the terminal.

Old and Long Cables (Both Battery Terminal)

Cables that are internally damaged or possibly exposed wires can formulate with other metallic parts and melt the terminal.

These cables also get into rough shape in time, causing damage to the terminal and melting it. Long cables take time to pass electricity, generating heat and melting the terminal.

High Resistance (Negative Battery Terminal)

When a battery operates, it goes through a lot of friction resistance. This can also cause the terminals to melt because we know resistance generates heat.

Another thing that can cause friction is the uneven surface of the terminal which creates an arc and melts the terminal.

Unfamiliar Reasons (Pre-heated Engine)

A preheated engine, due to direct sun exposure, can cause the terminal melting of a battery. Most cars are parked in the open sky day or night.

So, during the daytime, when the car engine is already heated, when someone starts the car, it melts the terminal slowly. However, it is mainly done under one closed roof where all the heat is stuck.

Jumper Cables (Negative Battery Terminal)

Using the wrong sides of the jumper cable can melt the terminal because of a person’s carelessness.

While using jumper cables, people don’t notice which side they are using, and that causes heat and arc that melts the terminal.

Inappropriate Contact with Surface (Positive Battery Terminal)

If the surface of the terminal and the lead wire is not interacting correctly, there will be a gap that will manifest heat in between that gap and create heat that will melt the terminal.

How To Replace Melted Battery Terminal?

Replacing a melted battery terminal is very easy if you follow the correct instructions step by step. By following the process, it can be done in 1 hour under 20 or 30 bucks.

Step 01: Safety Check and Removal

Firstly, check the battery terminals and the cables to ensure they are entirely disconnected from the machine. Then unbolt both of the terminals from the battery cable ends.

After that, use a wire brush or sandpaper to clean up the corrosion from the battery. You can use acid and water solutions to neutralize the battery, or you can always buy a battery terminal cleaner spray from a nearby hardware store.

Step 02: Buy a New and Good Quality Battery Cable Terminal

Suppose you want a battery cable terminal to last a long period without melting and avoid the extra cost. In that case, later on, you must buy the best possible cable terminal available to you.

We always prefer Copper Compression Terminals as they are not cheap quality as Lead Battery Terminals.

Step 03: Seal the entire Connection

Sealing the whole Connection with a heat-shrink tube will help to prevent it from corrosion. It is not expensive, but it will greatly help in the long term.

Step 04: Replacing the Battery Terminals

This part is a little complex for some people, but if you got the right tools (Hacksaw, pliers, ratchet set, and wrench set), the process becomes much more manageable.

Use pliers to hold the terminal while you hacksaw it from the cable. Cut half inches of each cable and clean it with a wire brush. Then slip the cable tubing over the cable.

Step 05: Tighten the Bolts and Test

After inserting the main cables through the compression nuts, put the bolts on the battery terminal and tighten them properly. But do not over-tighten them, as they can cause some damage afterward.

That’s it, and you can test the battery now with a multimeter to check the continuity of electricity through the cables.

How To Prevent Your Battery Terminal From Melting?

Most of the damage happens because of a lack of care, but with proper care and following some steps, anyone can make their battery last longer.

It is almost impossible to use one battery forever, but it is possible to use one for a very long time with good care.

Regular Check-Up

Checking your battery once in a while can help you to understand the condition of the battery cable terminals.

So, if you notice any inconsistency around the terminal, you can fix it before it gets worse. Ultimately it will prevent the battery terminals from melting.

Tighten the Bolts/ Nuts properly

A common mistake everyone makes is that they think it’s better to over-tighten the bolts. But in reality, it’s the opposite because when there is too much friction, it will generate heat.

So, to protect it from overheating, plug the bolts accurately. Not too tight, not too loose.

Carefully Use the Jumper Cables

When using jumper cables to start a car or use the battery, look carefully at which cable goes to the positive terminal and which goes to the negative. This little carefulness can remove the chances of melting.

Clean the terminals

Dust and rust can ruin your battery terminals as they are obstacles in between them. So, whenever you notice the battery is dirty, or the metal part got rusted, clean them with a wire brush and polish the surface. It will protect the battery from the unnecessary arc.

Coating and Park under Trees

One of the most helpful prevention methods is using Heavy Duty Metal Protector spray on the terminals. This coating reduces the chance of melting.

Another thing that can help from melting is parking your vehicle under shadow or using a sun reflector on the engine, reducing the heat inside the truck. As a result, the pre-heat won’t be an issue.


People have various questions relating to this topic. We tried our best to answer the frequently asked questions based on the matter below. Hopefully, you will find your answers as well.

How much does it cost to replace a battery terminal?

Battery terminals are much cheaper than an entire battery, so it is always an easy choice to replace the terminal when needed.
But it depends if you have the tools already at your home. Because if you don’t, it will cost you extra money to buy the tools.
It will cost around 20$ for good compression and another 10$ for cleaning materials.

Why does the positive terminal get hot?

Positive terminals can get hot for several reasons, such as a defective starter. Broken or damaged starts can create issues while transferring electricity.
Another reason can be incorrect contact with the terminal surface, which creates an arc and makes the terminal hot.
The positive terminal gets hot because of a faulty alternator because it puts extra pressure on the battery to generate power, and the terminal gets hot.

What happens if a car battery gets too hot?

Extreme heat can cause serious damage to the car, and it is very likely to cause a fire while the engine is still running. It is common to understand that if the battery gets too hot, it will melt the terminals.
So, if any terminals melt because of excess heat, it will be the origin of a severe accident, which can cause serious damage to the car.

Can I Use melted battery terminal before replacing it?

The clear answer to that question is “No” unless the terminal’s melted a little. Still, we don’t prefer to use a melted terminal because it can bring bigger problems like accidents or damaging the car, which can cost thousands of bucks.
If the terminal is melted slightly, you can use it for a few hours with the risk, but we still suggest not to use it in that condition.

What does a melted battery smell like?

A melted battery will produce Hydrogen Sulfide gas which smells pretty bad and is also harmful to health.
It can smell like rotten eggs or sewerage water because these two also contain the same type of gas.
It is a toxic gas formulated from the acid inside the battery, and you will instantly notice it because it will have a burning effect on your nose.


Finally, the overall idea is that the main culprit of the problem is heating, even though we are to blame for our carelessness about cable management and not taking proper care.

It is not a very tough job to check the battery condition regularly if someone wants to avoid the situation. Doing a little work, putting the cables correctly, and cleaning from time to time, anyone can save themselves from this problem.

The replacement process is so straightforward and low cost, but some of us avoid that little effort them pay a higher price later after having a bigger incident. It is better to solve the problem before it gets worse.

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