Tacoma Alternator Cable Install

Tacoma Alternator Cable Install

Posted by Dan Wagoner on

2024 Tacoma - DC-DC Charger Cable Install


  • 20’ - 4 AWG Wire – red
  • 20' - 1/2" wire loom
  • Qty. 1 - 4 AWG Lug – 5/16”
  • Qty. 1 – 1” length ½” Heat Shrink
  • Qty. 1 – Blue Sea 5191 Terminal Fuse Holder
  • Qty. 1 – Blue Sea 5178 60amp Terminal Fuse (good for 50amp charger)
  • Qty. 10 – 8” zip ties
  • Electrical Tape or Automotive Cloth Tape (preferred)
  • Qty. 1 - 5/8” Grommet
  • Qty. 1 - DC – DC Charger 

 Tools Needed:

  • Crimping tool for 4 AWG wire
  • Cable cutters
  • Wire cutters
  • Ratchet
  • 12 mm socket
  • 14 mm socket
  • 5/8” drill bit
  • Drill
  • Heat gun
  • Small flat head screwdriver


  • Safety First:  Disconnect the negative terminal of the vehicle’s starting battery to prevent any electrical accidents.
    • Remove Rear Passenger Seat - see seat removal instructions
    • Choose a Mounting Location:  Select a suitable location for the DC-DC charger behind the passenger rear seat.  SXTH Element offers a mounting plate for your electrical system if you need one. 
    • Remove the trim entry trim piece by simply pulling up on the front edge.


    • Remove the Passenger Seat Storage Bin Cover:  Push the center of the clips and pull them out.  


    • Pull the assembly forward towards the passenger seat to remove it.
    • Prepare the Alternator Cable
      • Measure and cut the alternator cable to the appropriate length.
      • Wrap the cable in wire loom and tape it periodically to keep the loom in place.    
    • Prepare the stock wire gland:
      • Cut a small hole in the stock wire gland under the Passenger Seat storage bin.  Careful!!! Do not cut the stock wire harness here.
    • Route the Alternator Charge Wire:
      • Run the wire from the main battery positive terminal down behind the  passenger side wheel well as viewed.  The wire should be zip tied in several locations to ensure it doesn't get close to the exhaust pipe and it should land on top of the frame.  
    • Route the Alternator Charge Wire:
      • Run the wire along the top of the frame and secure it in several locations using zip ties.  


    • Insert wire into stock wire gland:
      • Insert the wire into the stock wire gland and set it to the side.


    •   Prepare the Passenger Seat Storage Bin Trim for Wire:
      • Position the trim so that you can drill a 5/8" hole.  In this example we carefully put the piece into a vice.  Drill a 5/8" hole in the location shown.


    •  Prepare the Passenger Seat Storage Bin Trim for Wire:
      • Insert a 5/8" grommet and cut an 'x' shaped slit into the center so that the wire can pass through.


    • Route the wire:
      • Insert the wire through the grommet and position it in such a way that you have enough slack to reinstall the trim.  Ensure there is enough wire to reach the location of your charger terminals.  Pro tip, leave lots of extra wire.    



    • Reinstall Passenger Seat Storage Bin Trim:
      • Reinstall the trim piece by positioning it carefully and pushing it towards the back of the truck to get the clips to engage.  Push the pins back into their respective holes and push the center down to lock them into place.


    • Reinstall entry trim:
      •  Line up the trim and press it down.

    • Prep Wire for Battery Connection:
      • Cut the wire to the correct length.  Strip the insulation, crimp the lug onto the wire, and apply the heat shrink over the lug.  



    *** Warning****  Do not hook up the battery until the charging cable is terminated onto the DC - DC Charger.  Stop here and install your charger.


    • Install Terminal Fuse Block:
      • Remove battery terminal nut and install the terminal fuse.  Tighten the nut back to specified torque spec.  Install the fuse and charging cable.


    • Install Terminal Covers:
      • Install battery positive terminal cover and terminal fuse cover.
    • Secure and Tidy Up:
      • Secure all zip ties and cut loose ends.
      • Ensure there are no loose connections and everything is neatly arranged. 
    • Program the Charger:
      • Use the manufacturers recommended method to program your charger for the battery you're using. 
    • Test the System:
      • Start the vehicle and check is the DC-DC charger is fucntioning as it should.


      • Refer to the DC-DC charger’s manual for specific installation instructions and safety guidelines.
      • Consult the vehicle’s owner manual for any specific considerations related to the electrical system.
      • If unsure about any step, seek professional assistance to avoid damaging the vehicle’s electrical system or causing a safety hazard.


        This guide is for informational purposes only. The actual installation may vary depending on the specific model of the DC-DC charger and the vehicle. Always follow the manufacturer’s instructions and take appropriate safety precautions.

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