Wiktor Wise
Electrical cord plugs may wear out or become damaged over time, but you can save your appliance by simply replacing the plug. This is a fix you can make yourself, but it's important to be cautious as poor replacement could lead to electrical shock or fire hazards. If the cord is frayed or has exposed wiring, you may need to replace the entire cord. If the plug is the only damaged part, you can cut the wire just below the base of the plug and remove the old plug. Be sure to unplug the device before working on it and, if the plug is still connected to a power source, turn off the power at the breaker.
How to Replace an Electrical Cord Plug
| Characteristics | Values |
|---|---|
| When to replace | When the plug prongs are bent or snapped, or the cord is frayed or has exposed wiring |
| Before starting work | Unplug the device or turn off power at the breaker if the plug is still in the outlet |
| Tools | Wire cutters, Phillips-head or flat-head screwdriver, electrical tape, knife or razor, gloves |
| Plug types | Self-connecting, terminal screw, two-prong, three-prong, polarized, non-polarized |
| Wire colours | Ground wire (green), neutral wire (white), hot wire (black) |
| Process | Cut the wire just below the base of the plug, unscrew the old plug, trim any damaged cord, open the new plug housing, bend the copper portion of each wire into a U-shape, attach wires to the new plug, screw the new plug together |
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What You'll Learn
When to replace the whole cord
It is important to replace power cords when they show signs of damage or wear and tear. This is because continuing to use a damaged or worn-out power cord can damage your devices and pose a serious safety risk, including electrical shock and fire.
Firstly, check the cord's insulation. If there are any cuts, cracks, exposed wires, or charring, replace the cord immediately. Broken insulation and exposed wires can cause the cord to overheat, leading to electrical fires or even death from electrocution.
Secondly, if the cord is frayed or has exposed wiring, it is time for a replacement. Replacing only the plug while leaving a damaged cord could still leave you at risk of electrical shock.
Thirdly, if the cord is not performing as it did when it was new, it may be time for a replacement. You can check this by testing the amperage on the cord. If it is not what it used to be, it indicates that the cord needs to be replaced.
Finally, if you have antique or vintage appliances with fabric-covered power cords, it is recommended to replace the whole cord instead of just the plug. The insulation in old cloth wiring deteriorates over time, increasing the fire hazard. Additionally, if the cord has been cut from the wall outlet or pulled out from its connection, it may be best to replace the entire cord to ensure a secure connection.
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How to remove the old plug
Before you begin, make sure the appliance is unplugged from the electrical socket. If the plug is damaged but still plugged in, turn off the power at the breaker before unplugging.
If your plug is polarised, mark the side with the wider prong with tape on the cord. Next, use electrical scissors, wire cutters, or a pair of sharp shears to cut the plug off the end of the power cord. You don't need to slit the insulation or remove any material or wire at this stage. If there is damage to the cord close to the plug, trim those parts off, too. The cord should be smooth and undamaged until the end where the plug is.
If your plug has two parts, with one piece containing the wiring connections and prongs and another that is an outer shell or body, slide only the outer shell onto the cord for now. Cut partially through the outer jacket of the cord, being careful not to cut through the insulation on the cord wires, which could create a serious shock or fire hazard. Split the jacket with your fingernails and peel the two sides apart, then trim off the loose jacket with wire cutters or a utility knife.
If your cord is not cloth or fabric, examine it closely. If only the plug prongs are bent or snapped, start by replacing the plug. If the cord itself is frayed or has exposed wiring, you may need to replace the entire electrical cord. If the damage is close to the plug, you may be able to retain the wire by cutting the cord at the damaged spot.
Make sure the plug matches the voltage rating and amperage of the wire. The number should be printed on the old and new plugs, so just make sure they match. Don't replace a three-prong plug with a two-prong plug or vice versa.
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Preparing the new plug
When preparing the new plug, ensure that it matches the voltage rating and amperage of the wire. The number should be printed on the old and new plugs, so make sure they align. Do not replace a three-prong plug with a two-prong plug or vice versa. If you are replacing a polarized plug, make sure the new plug is polarized too.
Before you begin, ensure the cord is unplugged from any power source. If your cord is not cloth or fabric, examine it closely. If the cord itself is frayed or has exposed wiring, you may need to replace the entire electrical cord. If the damage is close to the plug, you may be able to retain the wire by cutting the cord at the damaged spot.
Now, cut the wire just below the base of the plug. Take a wire cutter and align it about 1⁄4 in (0.64 cm) below the end of the plug. Cut straight through the wire to detach the old plug. If your plug has two parts, with one piece containing the wiring connections and prongs and another that is an outer shell or body, slide only the outer shell onto the cord for now.
Next, strip off 3⁄4 in (1.9 cm) of the cord jacket to expose the wires underneath. Use a wire stripper and wrap it around the cord 3⁄4 in (1.9 cm) from the end. Squeeze it and rotate it around the cord to cut through its outer housing. Then, slide the jacket off. This will expose the 2 or 3 wires underneath, depending on the type of cord. The ground wire is green, the neutral wire is white, and the hot wire is black. A 3-pronged cord has all three, and a 2-pronged cord only has a hot and neutral wire. Make sure you leave enough housing on the wires so you can still see the jacket colour. This is important for putting the wires in the correct place.
Finally, bend the copper portion of each wire into a U-shape. Grab the end of each wire and bend it backward to make a hook. This will make attaching them to the new plug much easier and more secure.
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Attaching the new plug
Firstly, open the new plug housing to fit it onto the cord. Typically, a Phillips-head screwdriver will do the job, but you may need a flat-head screwdriver. Next, strip off 3/4 inch (1.9 cm) of the cord's outer covering, known as the jacket, to expose the wires underneath. This can be done with a wire stripper, or carefully with a utility knife or razor blade. Be cautious not to cut too far back, as the wires should not be visible when you install the new plug. If you do cut too far, trim the wires so they are not too long.
The wires have different colour jackets, indicating their function: the ground wire is green, the neutral wire is white, and the hot wire is black. A 3-pronged cord will have all three, while a 2-pronged cord only has a hot and neutral wire. Ensure you leave enough of the wire jackets intact so that you can identify the colours when attaching the wires to the new plug.
Now, you can attach the wires to the new plug. First, bend the copper portion of each wire into a U-shape, then grab the end of each wire and bend it backward to make a hook. This makes it easier and more secure to attach them to the new plug. Finally, screw the housing of the replacement plug closed. On a 2-pronged plug, the housing will close like a clamp, and one or two screws will hold it together.
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Safety precautions
Safety is paramount when working with electricity, and replacing an electrical cord plug is no exception. Here are some crucial safety precautions to follow when undertaking this task:
Always unplug the device before working on it. If the plug is damaged but still plugged into an outlet, turn off the power at the breaker before unplugging. Working on a plugged-in device can lead to electrical shocks or short circuits, which can be extremely hazardous.
Inspect the cord and plug for any damage. If the cord is frayed, cracked, or damaged close to the plug, it is best to replace the entire cord rather than just the plug. A damaged cord can pose a fire risk, so always err on the side of caution.
When dealing with vintage appliances, proceed with extra caution. Old cloth wiring can deteriorate over time, increasing the fire hazard. Asbestos was also used as an insulator in pre-1980s appliances, so disturbing the cloth cord can release asbestos fibers into the air.
Ensure you have the correct replacement plug. Don't replace a three-prong plug with a two-prong plug or vice versa. If you're replacing a polarized plug, make sure the new plug is also polarized to prevent issues with reversed polarity and open circuits.
Use the right tools for the job. Don't use scissors or any tool not designed for cutting wires. Use electrical scissors, wire cutters, or sharp shears to achieve a clean cut without damaging the cord. Wear gloves and work on a flat surface to minimize the risk of injury.
Be mindful of wire placement. Wires have different color jackets that indicate their function. The ground wire is green, the neutral wire is white, and the hot wire is black. Leave enough housing on the wires so you can identify the colors, ensuring they are placed correctly in the new plug.
By following these safety precautions, you can help ensure that your device works safely and successfully after replacing the electrical cord plug.
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Frequently asked questions
If the plug is worn out or damaged, you may need to replace it. If the prongs are bent or snapped, start by replacing the plug. If the cord is frayed or has exposed wiring, you may need to replace the entire cord.
First, unplug the device. Using wire cutters, cut the wire 1/4 inch (0.64 cm) below the end of the plug. Then, cut the plug off the end of the power cord. Open the new plug housing with a Phillips-head or flat-head screwdriver. Unscrew the housing of the replacement plug and attach the wires.
First, unplug the device. If the cord is damaged, cut off the damaged parts. Mark the side of the wider prong with tape. Cut the plug off the end of the power cord. Open the new plug housing and unscrew it. Attach the wires, bending the copper portion of each wire into a U-shape first.
If you replace a three-prong plug with a two-prong plug or vice versa, you may be exposed to electrical shock. If you wrap damaged wiring in electrical tape, you may create a fire hazard. If you are working with vintage appliances, be aware that insulation in old cloth wiring deteriorates over time, increasing the fire hazard.
