Trystan Casey
Electrical cord plugs can wear out over time and may need to be replaced. This is a fix you can make yourself, but it is important to take safety precautions to avoid the risk of electrical shock. Before starting, make sure the device is unplugged and that the power is turned off at the breaker. When choosing a replacement plug, ensure that it matches the voltage rating and amperage of the wire, and that it is the correct type of plug for the cord you are fixing. There are three major types of replacement plugs: self-connecting, terminal screw, and three-prong. Once you have the correct plug, you can remove the old one and attach the new one by following the correct wiring instructions for your plug type.
| Characteristics | Values |
|---|---|
| When to fix a plug | When the cord is damaged or worn out |
| When to replace the whole cord | When the damage is close to the plug or at the end of the cord |
| When to call a professional | When dealing with antique appliances that may contain asbestos |
| Before starting work | Unplug the device and ensure it is turned off at the breaker |
| Tools | Wire strippers, electrical scissors/wire cutters/sharp shears, a knife, a screwdriver, a soldering iron, a heat gun, a continuity tester or multimeter |
| Plug types | Self-connecting, terminal screw, three-prong, polarized, non-polarized |
| Wire types | Hot wire (smooth), neutral wire (with ridges or a white stripe), ground wire |
| Steps | Buy the same style of plug; remove the old plug; cut off damaged parts of the cord; strip the wires; splice the wires, matching colours or ridges with smooth sides; cover the repair with a PVC shrink tube; attach the wires to the new plug; slide the plug case onto the cord; test the new plug |
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What You'll Learn
Cut the cord at the damaged spot
Before attempting to fix an electrical cord, it is important to take safety precautions to avoid the risk of electrical shock. Always ensure that the device is unplugged and, if it is still plugged into an outlet, turn off the power at the breaker before unplugging.
If the damage to the electrical cord is close to the plug, you may be able to repair it by cutting the cord at the damaged spot. First, examine the cord and cut off any parts with cuts or nicks. Use electrical scissors, wire cutters, or sharp shears to make a clean cut, removing the damaged section of the cord. Be cautious when cutting to avoid nicking the interior wiring. If you accidentally cut the wire, start over.
Once you have removed the damaged portion, strip off about 1 to 1-1/2 inches of the outer covering using wire strippers. Cut away the interior insulation, being careful not to cut the wires themselves. You should now see the black and white wires. If you do not have a white wire, look for ridges along the length of the wire, which indicate the neutral wire. The hot wire will be smooth.
At this point, you can proceed to attach the wires to the plug. It is important to match the wires to the correct blades or screws. Join the black wire to the brass or silver blade/screw, and the white wire to the silver or gold blade/screw. If your cord has a green wire, this is the ground wire and should be connected to a green screw. Ensure that you twist and wind the wires tightly around the screws to secure them in place.
Finally, slide the plug case onto the cord, ensuring that the blades are properly oriented and upright at a 90-degree angle to the case. Test your repair by plugging in the device and verifying that it is functioning properly.
Note: If you are working with vintage appliances or cloth-covered cords, proceed with caution as they may contain asbestos. In such cases, it is recommended to replace the entire cord or seek professional assistance.
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Remove the old plug
Before you start, make sure the device is unplugged from the power outlet. If the plug is damaged but still plugged in, turn off the power at the breaker before unplugging.
If the damage is close to the plug, you may be able to salvage the wire by cutting the cord at the damaged spot. If the cord is fabric-covered, it is likely best to replace the whole cord instead of just the plug. Asbestos was used as an insulator in appliances made before the 1980s, so cutting into a cloth cord could release fibres into the air.
To remove the old plug, start by examining the cord and cutting off any parts with cuts or nicks. Use wire strippers to strip off about 1.5 inches of the outer covering, bending the cord back and forth as you do so. Be careful not to cut the wire inside while removing the outer covering. Cut away the interior cloth insulation, leaving only the wires. If you are reusing a plug, push out the yellow insert from the centre of the plug by inserting a screwdriver through the cord end.
If the plug is polarized, it will have one blade wider than the other. Mark the side with the wider prong with tape on the cord. Using electrical scissors, wire cutters, or sharp shears, cut the plug off the end of the power cord.
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Strip the wires
Stripping the wires is an essential step in repairing an electrical cord plug. It involves removing the plastic insulation from the wires to expose the bare conductor, which will then be connected to the new plug. Here is a detailed guide on how to strip the wires:
First, identify the type of wire you are working with. Electrical wires come in several varieties, such as coaxial cable, lamp cord, non-metallic (NM) cable, solid core wire, and stranded wire. Knowing the type of wire will help you choose the appropriate tools and techniques.
Next, determine the wire gauge size. The gauge will indicate the thickness of the wire and is typically printed on the wire's insulation. Common sizes include 12-gauge and 14-gauge wires. This information will help you select the correct notch on your wire stripper.
Now, it's time to use a wire stripper to remove the insulation. Choose a wire stripper that accommodates the wire gauge you are working with. Insert the wire into the corresponding gauge slot in the stripper's jaws. Squeeze the handles and pull the stripper away from the wire to remove the insulation without damaging the underlying wire. If you don't have a wire stripper, you can use needle-nose pliers, scissors, or a utility knife, but be extremely cautious to avoid cutting or nicking the wire.
After removing the insulation, inspect the wires to ensure that no strands have been accidentally cut. If everything looks intact, twist the strands tightly between your fingers and form each wire into a hook shape. This will create a solid connection when attaching the wires to the new plug.
Finally, proceed with connecting the stripped wires to the new plug. Match the wire colours or the ridge side with the smooth side to ensure proper polarity. For example, connect the black or hot wire to the brass or gold screw, and the white or neutral wire to the silver screw. Secure the connection by wrapping the wire ends around the screws in a clockwise direction and tightening them.
By following these steps, you can effectively strip the wires and prepare them for a safe and successful connection to the new plug.
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Splice the wires together
Before you begin splicing wires, it is important to ensure that you have disconnected power from the wires. Unplug the device that you are splicing wires to if you can. If the wire is in the wall or can't be unplugged, turn off the circuit leading to the area to avoid getting shocked while working. If you can't disconnect the power, do not attempt to splice the wire, or you could get electrocuted.
The National Electrical Code (NEC) approves of using UL-approved wire connectors that are joined inside an approved electrical box. These connectors can be the familiar twist-on wire nuts or newer-style push-fit connectors. Either wire nuts or push-fit connectors are acceptable, as long as there is sufficient space in the box to contain them.
If you are working on multiple wiring projects, use different colours of electric tape to mark which wires are connected. Slide one of the exposed wires into the end of your butt splice. Butt splices are small tubes with openings on each end to insert wires. Take one of your wires and place it in the centre of the butt splice. Push the exposed end until it is in the middle of the splice. Use a wire crimper one-quarter of the way in from the end of the splice. Match the crimper hole to the size of your butt splice. Place the jaws of the crimper 1⁄4–1⁄2 in (0.64–1.27 cm) from the edge of the butt splice. Squeeze the crimper handles all the way so the wire is held in place.
If you are splicing wires, you can use a screw-on butt cap to connect two wires very easily. Securely splice thicker wires using a shrink tube to create a butt splice. For the most secure connection, solder the two wires together. Slide a 3-inch (7.6 cm) piece of shrink tube onto one of the wires. Shrink tubes are made from plastic that gets smaller when heated. Slide a piece of the shrink tube onto your wires before you splice them so you can easily slide it into place once you are finished. You don't need to use a shrink tube if you are splicing with a wire cap.
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Attach the wires to the new plug
Attaching the wires to the new plug is a crucial step in fixing an electrical cord. Here is a detailed guide on how to do it:
Firstly, identify the type of plug you are dealing with. Modern plugs typically have colour-coded screws, with the hot wire connecting to a gold or brass screw and the neutral wire connecting to a silver screw. If your plug has a green screw, it is for the ground wire.
Before attaching the wires, ensure that you have stripped away the correct amount of insulation from each wire. Stripping off half to three-quarters of an inch is usually sufficient. Check the gauge marked on the cord to determine the appropriate amount. It is important to avoid nicking the interior wiring when stripping the insulation.
Now, you can start attaching the wires. Twist the exposed wire strands tightly between your fingers and form each wire into a hook shape. This creates a secure connection. Attach the black or hot wire to the brass or gold screw, and the white or neutral wire to the silver screw. If your plug has a green screw for the ground wire, connect it accordingly.
Loosen each screw just enough to allow you to wrap the hooked wire end around it. Wind the free end of the wire in a clockwise direction around the screw. This ensures that the wire stays in place as you tighten the screw. Squeeze the hook end closed around the screw and tighten it securely. Hold the wire strands in place as you tighten to ensure a firm connection.
Finally, slide the plug case onto the cord and fit the blades into the correct orientation. They should be upright at a 90-degree angle to the case. If your plug has a yellow tab, insert it between the blades to keep the wires separate and the blades in place.
By carefully following these steps, you can securely attach the wires to the new plug. Always ensure that you are working with a safe power supply and take appropriate precautions to avoid any electrical hazards.
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Frequently asked questions
First, make sure the plug is the only damaged area. If the cord is damaged, you may need to replace the whole thing. If the plug is damaged, unplug the device and cut the plug off the end of the power cord. Buy a replacement plug that matches the voltage rating and amperage of the wire. Slide the plug case onto the cord, attach the wires to the correct blades, and slide the plug case up the cord so that the blades are at a 90-degree angle to the case. Put the yellow tab back in between the blades and plug in your device to test it out.
If your plug is polarized, mark the side with the wider prong with tape before you cut it off. When you attach the wires to the new plug, make sure the wider blade (the neutral connection) is attached to the side of the cord with the ribbing or white stripe.
Working with electrical wires is dangerous, so take all possible safety precautions to avoid the risk of electrical shock. Never handle a live wire. If the damage is close to the plug, cut the cord at the damaged spot instead of wrapping the wire in electrical tape.
