Fixing the charging cable

Discussion in 'Gen 1 Prius Plug-in 2012-2015' started by Sanjath, Jul 6, 2017.

  1. Sanjath

    Sanjath Member

    Joined:
    Aug 14, 2012
    107
    23
    0
    Location:
    SF Bay Area
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    My original charger stopped functioning after 4.5 years. For last year or so it seemed like it had a loose connection somewhere and once I folded the cable near the socket and taped it, it worked. Now it completely stopped, IIRC, it costs quite a bit to replace it.

    I was wondering if I could just open it and fix (assuming that some wire is coming loose). So, while I tried to see how I can open, I hit a road block, the screw head (drive) it has doesnt seem to match any tool I have or what ever I could see in Lowes. I searched the List of screw drives - Wikipedia, no luck.

    Can any of you tell me what kind of screw head it is and is it a reasonable thing to try to open and fix it?

    Here is the picture of the screw upload_2017-7-5_22-36-55.png

    Thanks in advance.
     

    Attached Files:

  2. gallde

    gallde Active Member

    Joined:
    Jul 29, 2004
    238
    130
    0
    Location:
    Tarrytown, NY
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Advanced
    Sanjath, bisco and Pluggo like this.
  3. gallde

    gallde Active Member

    Joined:
    Jul 29, 2004
    238
    130
    0
    Location:
    Tarrytown, NY
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Advanced
    You might also find the cable "strain relief" clamps hard to figure out. I gave up on trying to release the cables on mine, since the charger was covered by my extended warranty.
     
    Sanjath likes this.
  4. iluvmacs

    iluvmacs Member

    Joined:
    Nov 17, 2005
    280
    104
    0
    Location:
    Madison, WI, USA
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    I'm sorry, but what made you think that it was okay from a safety perspective to keep using it if you "folded the cable near the socket and taped it"? That's a fire hazard waiting to happen. Don't use it until it's fixed or replaced.
     
    Sanjath likes this.
  5. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,444
    50,202
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    i would rip her open and see if you can make repairs. then put it all back together in a safe manner. no reason why it can't be fixed, evseupgrade does it all the time.
     
    Sanjath likes this.
  6. Sanjath

    Sanjath Member

    Joined:
    Aug 14, 2012
    107
    23
    0
    Location:
    SF Bay Area
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    Agreed, I dont know what I was thinking :(. I also remember that it was around the same time I discovered that the inner washer (within the socket) also had come loose and coming in the way of properly latching it. So, I removed the misaligned washer and things worked. I thought folding may not have been required. But, anyway... yeah I should've tried to fix it right then.
     
  7. Sanjath

    Sanjath Member

    Joined:
    Aug 14, 2012
    107
    23
    0
    Location:
    SF Bay Area
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    Most of the things I seem to find are for iphone and macbook. I am not sure if those are too small for the charger unit. I am bit hesitent to order from internet and finding it that it doesn't work.

    I am going ahead and ordering this from amazon.


    Let me see if that works.
     
  8. mmmodem

    mmmodem Senior Taste Tester

    Joined:
    Nov 17, 2011
    2,732
    1,703
    0
    Location:
    Bay Area, CA
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    Do you know what caused the tear? Did you drive over it or anything? I don't take care of my EVSE but it seems to have held up pretty well. A good portion of the time it is out doors where I charge at work.
     
  9. Sanjath

    Sanjath Member

    Joined:
    Aug 14, 2012
    107
    23
    0
    Location:
    SF Bay Area
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    It seems to twist and wrangle a lot, my guess is that it may have caused it. I haven't driven over it or anything. It may have been dropped few times, but no crack or any damage on the unit apart from this seemingly loose connection.
     
    mmmodem likes this.
  10. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,444
    50,202
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    some people fail to hang the brick, and let it dangle from the plug.
     
  11. markabele

    markabele owner of PiP, then Leaf, then Model 3

    Joined:
    Mar 27, 2012
    5,084
    1,782
    1
    Location:
    Nebraska
    Vehicle:
    2018 Tesla Model 3
    Model:
    N/A
    I've let it dangle from the plug since the beginning and haven't had any issues.
     
  12. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,444
    50,202
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    past performance is no guarantee of future returns.:p
     
    mmmodem likes this.
  13. markabele

    markabele owner of PiP, then Leaf, then Model 3

    Joined:
    Mar 27, 2012
    5,084
    1,782
    1
    Location:
    Nebraska
    Vehicle:
    2018 Tesla Model 3
    Model:
    N/A
    I've never heard of a cord failing because it dangled. Even if this is the case with this one, we have no proof.
     
    bisco likes this.
  14. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,444
    50,202
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    agreed. it's in the manual, i go by it. but i pick and choose my poison.
     
  15. Sanjath

    Sanjath Member

    Joined:
    Aug 14, 2012
    107
    23
    0
    Location:
    SF Bay Area
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    As I thought it is pretty small. It doesn't work. I dont know how to search for this driver!
     
  16. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,444
    50,202
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    can you get a tool with all the sizes?