There's only one way to fix a damaged electrical cord plug and that's to replace it with a new one. Most electrical cords today come with a moulded plug that's an integral part of the cord itself. Original equipment manufacturer (OEM) cord sets, like the power cords on your toaster, washing machine and clothes dryer, are moulded assemblies of cord and cord caps. There are two approaches to repairing a damaged moulded plug: You can replace the complete cord set with a new cord set, or you can replace just the plug itself. In most cases the latter approach to the repair is the quickest and least expensive.
- Skill level:
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Things you need
- Razor knife
- Diagonal pliers/wire cutters
- Wire strippers
- Soldering iron
- Soldering sponge
- Rosin core solder
- Needle-nose pliers
Identify the type of plug that you are replacing. The National Electric Manufacturers Association (NEMA) classifies plugs and receptacles according to their amperage rating, voltage, number of poles and their blade configuration (straight blade or twist lock.). To help identify your plug, print out the two NEMA charts from references.
Using the diagonal pliers/wire cutters cut the old plug from the cord set. Take the old plug with you when you go to purchase the new plug so you can double-check the blade configuration.
Using the razor knife, carefully remove one and one-half inches of the outer jacket of the power cord being careful not to knick or damage the insulation on the individual conductors contained inside the jacket.
Disassemble the new plug, preparing it for installation on the cord set.
Insert the cord into the new plug body.
Using the wire strippers remove one-inch of insulation from the ends of the conductors. Twist the stranded conductors together in the clockwise direction.
Plug in the soldering iron and allow to heat up. Then clean the hot soldering iron tip on the wet soldering sponge.
Tin the clean soldering iron tip by applying a liberal coating of Rosin Core solder. A properly tinned tip will appear a bright, silvery colour.
Tin the ends of the stripped conductors by applying the hot iron to the underside while applying solder to the topside. Capillary action set up by the heat will cause the solder to flow around and through the stranded conductors.
Using the needle nose pliers, form loops in the end of the tinned conductors.
Place the loops in a clockwise direction under the terminal screws. The black, white, and green insulated conductors are attached to the brass, silver, and green screws, respectively.
Assemble the plug halves and tighten the cord restraint screws.
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