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Old 11-17-2010, 09:32 AM   #2 (permalink)
rbrowning
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"but both sets of posts output normal voltage"

This can be somewhat misleading. ANY amount of connection will show you with the correct voltage as long as you are not trying to conduct very much flow, and your volt meter is a very high resistance load with minimal current flow. I am guessing that the Autozone test included a load draw and the top posts have a poor connection inside. I was caught by this once when one strand of a copper wire was sticking out from a terminal and touching another at a limit switch. It provided enough current to turn on an indicator light but not enough to pull in a solenoid.

If you put a set of headlights across the batteries, I bet you will find that the good battery maintains its proper voltage and the suspect one has a lower voltage and the terminal may get hot.

I would suggest that you switch over to the other set of connectors.
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