Ford Mechanical Damage to Charge Cable

Physical damage to the Ford EV charger cable or handle (cuts, exposed wires, crushed sections) is visible.

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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

Vehicle driven over cable, Cable pinched in garage door, UV degradation of outdoor cable, Vandalism or accidental impact

How to Fix / Troubleshooting

Safety first: Immediately stop using a damaged cable. Turn OFF the breaker and do not plug the handle into any vehicle.

  • 1. Assess damage: Look for exposed copper, deep cuts, or deformation of the handle. Any such damage requires replacement.
  • 2. Do not tape or splice: Do not attempt to repair the cable with tape, wire nuts, or splices. EVSE cables must be replaced as a complete assembly.
  • 3. Order correct replacement: Obtain a Ford-compatible replacement charge cable and handle assembly rated for the charger’s current.
  • 4. Install replacement (power OFF): Remove the old cable from the internal terminals and strain relief, install the new cable, and torque terminals to spec.
  • 5. Test operation: Restore power and verify proper charging with the new cable.
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Repair Difficulty

Medium 3/5

Required Part

Ford Charge Cable and J1772 Handle Assembly
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