Grizzl-E
Overheating Connector / High Contact Resistance
J1772 handle becomes unusually warm or hot during charging
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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 loose J1772 contacts, Contamination on pins, Undersized or damaged cable conductors near handle, Prolonged high‑current operation with marginal contacts
How to Fix / Troubleshooting
Safety: Stop charging and disconnect the handle if it is too hot to touch.
- Inspect pins: Look for discoloration, pitting, or deformation on the J1772 pins. These are signs of overheating and poor contact.
- Clean contacts: Use a dry, non‑residue contact cleaner and a soft brush to clean the pins. Do not file or sand plated contacts.
- Check cable near handle: Feel along the cable near the handle for soft spots or bulges indicating internal damage.
- Resolution: If overheating recurs or pins are damaged, replace the entire EV charging cable assembly with J1772 connector.
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Repair Difficulty
Medium
3/5
Required Part
EV Charging Cable Assembly with J1772 Connector
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