Audi
Overheating Charging Cable / High Contact Resistance
Charging cable gets unusually hot during use with the Audi home charger, even at normal current levels.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Worn or oxidized contacts in Type 2 plug, Undersized or damaged cable conductors, Poor crimping at cable terminations inside wallbox, Continuous operation near maximum rated current in high ambient temperature
How to Fix / Troubleshooting
Safety first: If the cable is too hot to touch comfortably or shows signs of melting, stop charging immediately and switch off power.
- Inspect plug and inlet: Look for discoloration, pitting, or deformation on the metal pins of the Type 2 plug and the vehicle inlet. Replace the cable if contacts are damaged.
- Check cable rating: Confirm that the cable is rated for the charger’s maximum current (e.g., 32 A). Do not use lower-rated cables.
- Reduce current setting: Temporarily lower the maximum charging current in the Audi app or configuration to see if heating is reduced.
- Internal termination check: With power off, a technician should inspect and, if necessary, re-terminate the cable conductors at the wallbox end, ensuring proper torque and strain relief.
Replace any cable that shows visible damage or persistent overheating, even at reduced current.
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Repair Difficulty
Medium
3/5
Required Part
Type 2 Charging Cable Assembly
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