Changing an extension cord plug is a straightforward process that can repair a damaged cord or customize an existing one.
Changing the plug on an extension cord can extend its life and improve safety if the old plug is damaged. It typically involves cutting off the old plug, preparing the wire, connecting it to the new plug, and reassembling the plug body.
Essential Steps to Replace an Extension Cord Plug
Repairing a damaged plug is a practical skill that can save you from needing to buy a new extension cord. Follow these steps carefully, prioritizing safety at all times.
Step 1: Prepare for the Repair
- Safety First: Make absolutely sure the extension cord is unplugged from any power source. This is the most critical step to avoid electric shock.
- Assess Damage: Inspect the cord near the plug. If the cord itself is cracked, frayed, or significantly damaged beyond the plug, it might be safer to replace the entire cord.
- Gather Tools: You will need a few basic tools.
Table: Tools Needed
| Tool | Purpose |
|---|---|
| Wire Cutters | Cutting the old plug and damaged cord |
| Wire Strippers | Removing insulation from wires |
| Screwdriver | Securing wires to terminals |
| Replacement Plug | The new plug itself |
| Utility Knife | Slitting outer cord jacket (optional) |
Step 2: Remove the Old Plug
- Using wire cutters, cut off the old plug from the cord.
- If there is any damage to the cord beyond the plug, cut off any damaged portion at the end of the cord as well to ensure a clean, safe end.
Step 3: Prepare the Cord End
- Most replacement plugs are designed to clamp onto the outer jacket of the cord for strain relief. Slide the new plug over the cut end of the cord and out of the way for now. You will need to access the bare wires later.
- Carefully use a utility knife or wire strippers to cut through the outer jacket of the extension cord, about 1 to 1.5 inches (approx. 2.5-4 cm) from the end. Be careful not to cut into the insulation of the individual wires inside.
- Remove the piece of outer jacket to expose the insulated wires (usually black, white, and green).
- Use wire strippers to remove about 1/2 inch (approx. 1.2 cm) of insulation from the end of each of the three wires.
Step 4: Wire the New Plug
- New plugs typically consist of a body (which you already slid onto the cord) and a terminal assembly with screw terminals. Some may also have a cord clamp.
- Identify the screw terminals:
- The green screw is for the ground wire (usually a round, longer prong on the plug).
- The silver or white screw is for the neutral wire (usually the wider prong).
- The brass or darker screw is for the hot or live wire (usually the narrower prong).
- Twist the strands of each exposed wire end tightly together.
- Connect each wire to its corresponding screw terminal:
- Loosen the screw terminal.
- Bend the bare wire end into a U-shape hook.
- Place the hook around the screw in a clockwise direction (so the screw tightens the loop as you turn it).
- Tighten the screw firmly. Ensure no stray wire strands are sticking out.
- Repeat for all three wires (green to green screw, white to silver screw, black/hot to brass screw).
Step 5: Reassemble the Plug
- Carefully position the terminal assembly with the wired connections into the plug body.
- Ensure the wires are not pinched and are routed correctly inside the plug.
- Secure the plug body components together. This might involve snapping halves together, tightening screws, or securing a cord clamp onto the outer jacket of the cord. The cord clamp helps prevent the wires from pulling out of the terminals.
Important Safety Tips
- Always work with the cord unplugged.
- Use the correct type of replacement plug for your cord (e.g., grounded 3-prong plug for a 3-wire grounded cord).
- Ensure all screw terminals are tightened firmly. Loose connections can cause heat build-up and fire hazards.
- Double-check that no bare wire strands are exposed outside of the screw terminals or touching other terminals.
- Test the cord in a safe environment (e.g., plug in a lamp with a switch turned off, then plug the cord into a wall outlet and turn on the lamp).
Replacing an extension cord plug can be a cost-effective repair, but it's crucial to follow these steps carefully to ensure the cord is safe to use. If you are uncomfortable working with electrical wiring, it's best to consult a qualified electrician or replace the entire extension cord.
