Leviton Connector Arcing / Poor Contact

Visible arcing or sparking at the J1772 connector when plugging in or unplugging, sometimes accompanied by a burning smell.

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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 contact springs, Contaminated or corroded pins, Plugging/unplugging under load due to delayed contactor opening, Damaged vehicle inlet contacts

How to Fix / Troubleshooting

Safety first: Stop using the charger immediately. Turn OFF power at the breaker. Do not continue to plug or unplug if arcing is observed.

Steps:

  • 1. Inspect connector: With power OFF, examine the J1772 handle for burn marks, pitting on pins, or melted plastic.
  • 2. Check vehicle inlet: Look into the vehicle’s charge port for similar damage. If present, contact the vehicle manufacturer.
  • 3. Replace damaged parts: If the Leviton connector shows any signs of arcing damage, replace the entire cable and connector assembly.
  • 4. Verify contactor timing (technician): A technician can confirm that the internal contactor opens before the connector is removed, as per design.
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Repair Difficulty

Medium 3/5

Required Part

Leviton EVSE Charge Cable and J1772 Connector Assembly
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