Chevrolet Intermittent Contactor Operation / Unstable Charging Session

Charger clicks repeatedly and starts/stops charging every few seconds.

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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

Loose pilot or proximity connection, Weak contactor coil, Control board sensing unstable voltage, Vehicle-side charging module rapidly connecting/disconnecting

How to Fix / Troubleshooting

Safety first: Repeated contactor operation can cause wear and arcing. Turn OFF power before opening the unit.

  • Step 1 – Try another vehicle: If possible, test with a different EV to determine if the issue is vehicle-specific.
  • Step 2 – Inspect connector and cable: Check for loose fit in the vehicle inlet, damaged latch, or heavy strain on the cable that might disturb the connection.
  • Step 3 – Check supply voltage stability: Have an electrician verify that the supply voltage does not sag or fluctuate significantly when the charger engages.
  • Step 4 – Internal inspection: With power OFF, inspect the contactor and control board for signs of overheating or loose control wires.
  • Step 5 – Service contactor/board: If the problem persists across vehicles and the supply is stable, the contactor or control logic may need replacement.
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Repair Difficulty

Hard 4/5

Required Part

Main Power Contactor Assembly
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