Charging cable stuck in PIP - Any ideas?

Sounds like the seal is crimped in the charge plug. Try pushing it in as much as possible and then try slightly tilting at each 90 degree and then attempting to pull it out. Also see if you can wiggle it slightly while trying to pull it out. Just make sure the release button is being pressed when you do this.

 

Oh dear!
I think the fact the connector was getting difficult to insert/remove should have been a flag. As for tips, I'm not sure about removal, although care might be needed to avoid breaking something. I would think the first thing to do after (and when/if) you're successful in removing it, might be to carefully clean the whole thing, body, mating surfaces, catch, prongs, and perhaps even spray some non-conductive lube (I'm not sure about WD-40, I think I might use a silicone-based spray, similar to the stuff put on ski-bindings to lube them, and help prevent snow/ice building up on their surfaces). Good luck, Danny! …you've certainly come to the right place to find solutions!

 

WD40 won't damage anything, might melt the goo that's sticking, di-electric grease before reinsertion might be good, if it's not metal on metal crimped, I'd think it was a build up of grease or grime.

 

How funny. I just logged in to search this same identical problem. The cable was getting more and more difficult to insert and today it won't come out. I can see the silver latch lifting up at the end of the connector when I press the release button, so that doesn't appear to be the issue.

 

Solved my problem just now. With the harder insertion and removal resistance over the last month, it seems the locking mechanism from the plug handle was periodically pulling up on the metal plate at the top of the car connector socket. The little metal plate acts like a ramp for the lock to be lifted up and over the ledge to actually lock the plug into the car. That little metal ramp was rising up higher than the handle lock could lift when trying to release the handle. With a screwdriver I was able to push the metal ramp down as I released the handle lock. Then it came out. I then pushed it back down to where the handle lock could be lifted over it without using the screwdriver.

I then proceeded to remove the orange insert inside the handle plug that was causing the heavy resistance when inserting the plug into the socket. It didn't look easy to reposition and I expected I would be doing this same procedure again. Hopefully it will still work reliably without that orange gasket because with it the daily connection routine was ridiculous.

 

the aftermarket j1773 handles don't have the gasket, so i don't think it's necessary.

 

you could flatbed it to the dealer, and they will be stumped.

 

I must say, I do not completely understand kentsmith description of the source of the problem he had.
The 'ramp' in my car side connector, that the latch lever slides-on it to lock, is all plastic, part of the connector, no separate metal plate that can move up (or down).
I think that it can be that a foreign object / dirt may have entered the gap between the back of the latch lever and the handle top over it, so the latch is not travelling all the way up when trying to release it (and resistance felt when connecting too).
The screwdriver advice is a good one though, helping the finger press to force the lever to displace enough to be released.
Once released, I would check the handle / lever for any foreign object / dirt that may cause the problem of partial displacement.
@Danny did you release the handle?

 

I've never had my clipper creek get stuck but on occasion it will begin to have some resistance. When that happens, I give the handle a quick shot of teflon dry lube spray.

 

Just to be sure...
The metal plate (or block?) you are talking about...is it the piece I have painted blue below?

 

wow, you're just a commoner, like the rest of us plebes.

 

I had to remove the orange rubber thing. That doesn't keep out water or do something else important, right?

 

right. the aftermarket ones don't even come with it.

 

I got rid of the rubber gasket the first time it started gumming up the works about a year in - haven't had any problems for three years through rain and shine, so it's probably not something that absolutely needed to be installed in the first place.

 

This post was very helpful this weekend when I couldn't disconnect my charging cable from my 2013 PiP. I ended up unbolting the port from the car as shown in Danny's photo - which was very easy. Thanks to all!

If you are hesitant to remove the rubber gasket, don't be. I took my car into a dealership this morning and found out that Toyota has a service bulletin about this problem. The dealership got rid of the rubber gasket for me and sent me on my way... so in case anyone is wondering, that seems to be the official way to fix it.

 

My charging cable was also stuck for the same reason. After prying it off I managed to rip off the metal clip, shaded in blue in this picture. Am I fine without it or do I need to schedule a service call with Toyota?

Thanks!