Symptoms
- Visible cracks, cuts, or fraying in the cable's outer jacket
- Exposed wires or discoloration at any point along the cable
- Cable feels stiff, brittle, or damaged from sun exposure
- Damage near the plug or connector ends specifically
Likely causes
- CommonWear from repeated bending and coilingCables that are tightly coiled or bent at the same points repeatedly can develop stress cracks over time.
- CommonSun and weather exposureUV exposure and temperature extremes can make the outer cable jacket brittle and prone to cracking.
- PossiblePhysical damage from being run over or pinchedAccidentally driving over the cable or catching it in a door can cause both visible and hidden internal damage.
- Less commonRodent damageCables stored in garages or outdoors can occasionally be chewed by rodents.
What to do
- Inspect the entire length of the cable, including near both ends, in good light for cracks, cuts, or exposed wire.
- Stop using any cable with visible exposed wiring or significant cracking; do not attempt to tape over or continue using it.
- Store cables loosely coiled rather than tightly wound to reduce stress-related cracking over time.
- Keep cables out of direct sun and extreme heat when not in use, using a cover or garage storage if possible.
- Avoid running the cable where it could be driven over, pinched in a door, or stepped on repeatedly.
- Replace a damaged cable with a manufacturer-approved or certified replacement rather than a generic uncertified one.
Tools and parts
Replacement charging cableSearch: “certified EV charging cable replacement matching your charger and car”
When to call a pro
If you're unsure whether damage is safe to keep using, contact the manufacturer or an EV-certified electrician for an assessment.
Safety
Use caution
Never use a charging cable with exposed wiring or significant damage; this is a shock and fire risk and the cable should be replaced immediately.