Repair battery terminal

To cut a long story short I have an AGM battery that has the negative terminal broken off. It seems to fit back inside the hole which still has a brass base ie. no hole directly into the battery. Given this battery has performed faultlessly and is being replaced at no cost to me after some discussion with my local Toyota dealer is it possible to fix it?

Next question is how?

Thanks,
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Reply By: Ianw - Tuesday, Dec 07, 2010 at 18:31

Tuesday, Dec 07, 2010 at 18:31
Can you drill a hole in the brass and tap a thread into it? Then just screw a terminal onto it.

Ian
AnswerID: 438146

Reply By: Battery Value Pty Ltd - Tuesday, Dec 07, 2010 at 19:20

Tuesday, Dec 07, 2010 at 19:20
tdv,

depends how thick the remainder of the terminal is.
If >6mm, you could tap it with M4.
But this is only for low currents <20A.

If not, you could try this:

the terminals usually are elbow shaped, one leg exposed, and the other runs parallel to the surface, a few mm under the black/red sealing compound.
So you could try to carefully scrape/chisel a 5 mm wide groove along the center line of this sealing compound.
If you accidentally damage the battery lid, seal it immediately with a piece of plastic sheeting and Araldite (there's a gas pressure differential of about 4~6 psi between inside and outside of the AGM battery during normal operation)
Once enough metal is exposed, drill and tap.
Make a stud by cutting off the head of a suitable bolt followed by starwasher and locknut.
Then a normal nut followed by another starwasher.
Now you can use a suitable wing nut to secure your wire lugs to the stud.

And don't smoke while doing this.
And please wear safety glasses just in case something goes pop.

cheers, Peter
AnswerID: 438148

Follow Up By: tdv - Wednesday, Dec 08, 2010 at 14:56

Wednesday, Dec 08, 2010 at 14:56
Mine is an Absorbed Power brand. It has/had a stainless allen key nut down the centre which has been sheared off inside.

I will see if there is space to do what you suggest. Thanks for the tip.
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FollowupID: 709892

Follow Up By: tdv - Thursday, Dec 09, 2010 at 10:09

Thursday, Dec 09, 2010 at 10:09
Thanks for the assistance. It turns out that the existing thread was just full of crud, not a sheared bolt. I was able to get a longer stainless bolt to fit and have re-attached the post like new! Looks like I now have additional power source for the camper!

Thanks again
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FollowupID: 710073

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