Ford Overheating Connector or Cable Without Trip

Charger or cable becomes excessively hot to the touch during normal charging, but no error code appears.

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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

High resistance at plug contacts due to wear, Undersized or long branch circuit wiring causing voltage drop, Loose internal terminal connections, Continuous operation at maximum rated current in high ambient temperature

How to Fix / Troubleshooting

Safety first: If the cable or handle is too hot to hold, stop charging immediately and turn OFF the breaker.

  • 1. Reduce current: If your vehicle allows, lower the charge current setting and see if temperatures remain reasonable.
  • 2. Inspect contacts: Check the J1772 pins and vehicle inlet for discoloration or pitting. Replace the cable if contacts are damaged.
  • 3. Check internal terminals (power OFF): Tighten all power lugs inside the charger to manufacturer torque specs.
  • 4. Evaluate circuit sizing: Have an electrician verify that the branch circuit wire gauge and breaker size are appropriate for the charger’s maximum current.
  • 5. Replace overheated components: Any melted or discolored parts (handle, cable, terminals) should be replaced.
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Repair Difficulty

Medium 3/5

Required Part

Ford Charge Cable and Internal Power Terminals
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