Volkswagen Overheating of Cable or Terminal Connections

VW wallbox or cable becomes excessively hot during charging; plastic feels soft or discolored; charging may stop intermittently.

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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 line or neutral terminal inside VW wallbox, Worn or damaged Type 2 plug contacts, Undersized supply conductors, Internal contactor contacts degraded

How to Fix / Troubleshooting

Safety first: If you notice burning smell, smoke, or very hot surfaces, immediately switch off the breaker and do not use the charger.

  • Touch test: After 10–15 minutes of charging, carefully touch the cable and plug. Warm is normal; too hot to hold is not.
  • Inspect plug: Look for discoloration, melting, or cracks on the Type 2 plug and vehicle inlet.
  • Reduce current: Temporarily lower the maximum current in the VW wallbox app to reduce heating.

A qualified electrician should open the VW wallbox, check torque on all terminals, inspect the main contactor and cable connections for discoloration, and replace any overheated components or the tethered cable assembly.

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Repair Difficulty

Hard 4/5

Required Part

VW wallbox tethered Type 2 cable
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