Whether you're using an extension cord in your garage, powering tools on the job site, or plugging in holiday lights—a broken plug can render the entire cord useless. The good news? Replacing a power cord plug is a simple, safe DIY task with the right tools and a little electrical know-how.
Follow this step-by-step guide to fix a broken or damaged male (plug) end of an electrical extension cord.
???? What You’ll Need
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Replacement plug (3-prong grounded plug recommended)
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Wire cutters / wire stripper
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Utility knife
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Small flathead screwdriver
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Voltage tester (optional, for final testing)
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Electrical tape (optional)
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Safety gloves
⚠️ Safety First
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Always unplug the extension cord from the power source before attempting any repair.
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Never repair a cord that is frayed or melted throughout—replace it instead.
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This guide is for 3-wire grounded extension cords (with black, white, and green wires).
???? Step-by-Step Instructions
Step 1: Cut Off the Damaged Plug
Use wire cutters to remove the broken or damaged plug from the end of the extension cord.
➡️ Cut cleanly, leaving a straight edge with enough cable length to work with.
Step 2: Strip the Outer Insulation
Use a utility knife to carefully remove about 1.5–2 inches of the outer jacket (rubber or vinyl).
➡️ Be gentle—don’t cut into the wires inside.
You should see three inner wires:
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Black (hot)
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White (neutral)
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Green or bare (ground)
Step 3: Strip the Inner Wires
Using wire strippers, strip about 1/2 inch of insulation from the tip of each inner wire.
➡️ The copper ends should be exposed cleanly.
Step 4: Connect Wires to the New Plug
Open the replacement plug housing and identify the terminal screws:
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Brass screw = Black (hot)
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Silver screw = White (neutral)
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Green screw = Green or bare (ground)
???? Insert each wire into its corresponding terminal and tighten the screws. Ensure:
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Wires are fully inserted.
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No stray copper strands are sticking out.
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Screws are firmly tightened.
Step 5: Reassemble the Plug Housing
Once all wires are attached:
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Fold the cord back into the plug housing.
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Screw or snap the plug closed.
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Make sure there’s strain relief (most plugs have a clamp that grips the cord to prevent pulling the wires out).
Step 6: Test the Cord
Plug the repaired cord into a working outlet and:
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Use a voltage tester or a simple device like a lamp to check functionality.
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Ensure there’s no sparking, heat, or flickering.
✅ Success! You’ve restored your extension cord safely.
???? Extra Tips
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Choose a heavy-duty plug for high-amperage cords (15A or more).
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Use outdoor-rated plugs for cords exposed to moisture or weather.
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Avoid using super glue or makeshift repairs—use only electrical-grade materials.
???? When Not to Repair
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Melted, charred, or excessively brittle cords should not be repaired.
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If multiple areas are damaged, replace the cord entirely.
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Always adhere to local electrical codes—especially in commercial or industrial settings.
???? Recommended Products
Consider using industrial-grade extension cords from trusted manufacturers like Autac USA that offer durable, repairable designs built for longevity and safety.