Power System - Dual Battery


I removed the existing single group 24 battery in the TJ and built out a dual battery system with upgraded components.

Highlights
  • Installation of dual Odyssey 925M AGM Batteries.
  • I custom built my own battery bracketing system that uses the existing factory one. I machined out the parts I needed to adapt it so that an original standard vehicle battery could go back in if absolutely had to.
  • Replacement of the factory alternator with 160A high output one as well. This is a 160Amp High current alternator from PA Performance.
  • Installation of Painless 40102/3 power isolator system.
  • I custom built the box inside the cab that controls the isolator system, has LED's to show status and has a dual volt meter one for each battery.
  • Re-wired all major power and ground wires and upgraded from factory standard 8 gauge to all 2 gauge copper wires, complete with heat shrinked ends. I also re wire loomed the entire engine both new and factory wiring.
  • WARN Zeon 10s Platinum Winch power lines 1/0 Gauge wired directly to primary battery
Functioning Modes
  • Mode 1 - Switch right - Red LED Lit - Isolator connects both batteries together, at all times, even when vehicle is not running. Alternator will charge auxillary battery and primary battery. Either battery can drain the other, they are acting as one.
  • Mode 2 - Switch center - No LED Lit - Isolator solenoid is not active, batteries are disconnected from each other, regardless of vehicle state (running or not). Primary battery is charged by alternator, auxillary is not. Best mode for jump starting yourself.
  • Mode 3 - Switch left - Green LED Lit - The primary and auxillary batteries are connected when vehicle engine is running, but disconnected when vehicle is shut off. This allows both batteries to charge off alternator during normal operation of vehicle, but remain disconnected when vehicle is off, to prevent draining of primary battery due to auxillary battery usage. Best normal operation mode.
Parts
Down below are some highlight photos of a few items. If you want to view all the 100+ photos of the project including the battery bracket system build out, you can go to this gallery.
Password is: jeep - https://gallery.mclaughlin.cc/Vehicles/2005-Jeep-Wrangler-TJ-X/Jeep-Dual-Battery-Project-2020/

Click any photo for larger image
Final Wiring Diagram
Final DC Wiring Diagram
160A High Current Alternator
160A High Current Alternator
Custom built control box
Custom built control box
Inside view of Control Box
Inside view of Control Box
Dual Battery System Install
Aux Battery Power Control System
Aux Battery Power Control System
Aux Battery Power Control System
Aux Battery Power Control System
Custom Wires I built out of 2GA copper to replace shitty factory 8GA cables. Complete with heat shrinked ends.
Comparison. Factory shit box wire on the left, mine on the right



Copyright ©2024 - 2020 Jeep Inky