Laptop Charger plug repair (how to)

Thanks to their very “honest” design, laptop chargers tend to break relatively easy. The plug internally detaches from the wire, and momentarily works when the user bends or twist it. The solutions are simple: Buying and replacing the plug, or buying the whole (damn expensive) charger.

But if you don’t have time and money for that, I offer you a better, third option
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Wait!

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This repair only works when the plug is the problem: Charger LED is lit, computer doesn’t charge, but it does when the plug is bent or pushed. This tutorial doesn’t explain how to replace the whole cable (i.e. if your dog chewed it), but I’ll make a post about that later.

If the LED doesn’t turn on, I suggest you to check the other cable (the one that goes to the wall) using a multimeter.

If the cable is good but the LED remains off, bad news: maybe the jack detached from the charger circuit board, or in the worst case the charger electronics are fried.

In my example the LED is turned on, so we are ready to go

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Let’s do it

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Cut off all the plastic around the plug. Remember the Headphone plug repair post? Heating the knife will make the job easier. But please, watch your fingers!

REMEMBER THE POLARITY! That means, which wire is connected to the + and the – side of the plug. Do not forget it! or you will damage your computer

Ok, now its the turn for the wire. Cut away a few inches of the end, to make sure the damaged section is gone. Then strip the insulation as shown

Adding some solder to the copper (prior to soldering the plug) will make a better contact.

I say again: CHECK THE POLARITY!

Remove the excess and solder the plug as described on the picture. Very simple.

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Now comes “The Art”

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This is the most important of the post: I’ll teach you my ancient, patented technique. Is not very luxurious, but it’s free. I’m using common hot glue to rebuild the plug insulating body.

The shape grows progressively around the plug

Here’s another plug I did days earlier. Notice that I replaced the cable too.

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Finished Work

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Maybe is not very pretty, but works very good

It’s done!

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