Perhaps the most common damage comes from pulling out the plug by the cordnot the plug.
One more result of wear and tear is the ground prong coming loose.
When any of these forms of damage occur, it’s time to replace the plug.
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Just wrapping the damaged cord with electrical tape isn’t good enough.
Extension cords come in many forms, as do the replacement plugs used to fix them.
The project demonstrated here shows how to replace the plug on a typical medium-duty grounded extension cord.
The Spruce / Kevin Norris
Cut off the old plug from the cord, using wire cutters.
Cut off any damaged portion at the end of the cord.
Slide the new plug over the cut end of the cord and out of the way for now.
The Spruce / Kevin Norris
In this case, slide only the outer shell onto the cord for now.
Warning
The replacement plug must have the same amperage and voltage ratings as the original cord.
These ratings are printed on the plug.
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The ratings on the old plug will indicate the punch in you need.
The cut should extend 3 inches from the end of the cord.
Trim off the loose jacket with wire cutters or a utility knife.
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Use the notch on the strippers that precisely matches the diameter (gauge) of the wire.
This provides added protection against the cord wires separating from the plug connections if the cord is tugged.
Connect the Cord Wires
Using a screwdriver, loosen the terminal screws on the plug.
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Wrap the bare end of the black (hot) wire clockwise around the brass terminal.
Many new plugs have slots to insert the wire.
Tighten the screw down onto the wire.
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see to it that no stray wires are sticking out from the connection.
Wrapping the wire clockwise ensures that the wire loop tightens around the screw as the screw is tightened.
Double-check the connections for tightness by pulling gently on each wire.
The Spruce / Kevin Norris
Most newer plugs have a clamping connection that the wire slides straight into before tightening the screw.
This eliminates the need for wrapping the bare wire around the screws.
Secure the Plug
Using a screwdriver, tighten the plug clamp onto the cord.
