Wallbox Overheating Connector / High Contact Resistance

Wallbox charger’s cable or connector becomes very hot during charging, even at normal current levels.

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Possible Causes

Worn or contaminated connector pins, Loose crimp inside plug, Undersized or damaged cable, Poor contact in vehicle inlet

How to Fix / Troubleshooting

Safety first: Stop charging and turn off power if the connector is too hot to touch or shows signs of melting.

  • Visual inspection: Examine the connector pins and plastic body for discoloration, pitting, or deformation. Replace the connector/cable if any damage is found.
  • Clean contacts: If pins are dirty but not damaged, gently clean with a dry, lint‑free cloth. Do not use abrasives or liquids.
  • Check cable routing: Ensure the cable is not under tension or sharply bent near the connector, which can stress internal crimps.
  • Test with another EV or cable: If possible, test with a different vehicle or Wallbox cable to determine whether the issue is with the charger cable or the vehicle inlet.

Persistent overheating requires replacement of the cable assembly and possibly inspection of the vehicle inlet by a dealer.

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Repair Difficulty

Easy 2/5

Required Part

Charging Cable Assembly
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