How to Fix an Extension Cord

The extension cords used in most homes are relatively inexpensive and can be damaged easily. The damage might not become obvious until the cords stop working or start blowing fuses. The damage might be visible inside a cord's molded plugs and receptacles. The damage can be detected and repaired using some basic tools and test equipment.



Everything that you will need to make these repairs, including an inexpensive digital multimeter, can be found at a hardware store or home center.

• 1

  Connect the red and black test probes that came with you meter to the multimeter. Plug the "Black" test lead into the jack marked "COM" or "COMMON." The "COMMON" jack is also colored black. Plug the "Red" test lead into the jack marked "Volts/Ohms." This jack is also colored red.

• 2

  Set the "Function Switch" on the digital multimeter to the "Ohms" function.

• 3

  Check the extension cords continuity from end to end with the digital multimeter. Place one test probe on the wide prong on the plug and place the other test probe in one of the wide slots on the receptacle end of the cord. Continuity, a continuous wire from one end to the other, will be indicated by a reading of 0.000 to 0.500 Ohms on the meter's LCD. Some meters read the resistance of their internal fuse, hence the 0.500-Ohm reading. An open wire, a bad wire, will be indicated by an "O.L." on the LCD. Check the opposite side of the extension cord for continuity in the same manner. In most cases, the problem will be with the molded plug or receptacle and not the cord itself.

• 4

  Check the molded plug for continuity between each of the blades and the wire. Insert one of the test probes into the wire an inch or two from the plug. Push the sharp point into the wires insulation until it makes contact with the copper wire itself. Touch the other test probe to the plugs matching blade. An "O.L." indicates a bad connection. Check both sides of the plug in the same manner.

• 5

  Repeat step four for the molded receptacle end of the extension cord. Defective molded plugs or receptacles cannot be repaired, they need to be replaced. The procedure for replacing a molded plug or receptacle is the same.

• 6

  Using the wire cutters cut off the defective extension cord end, the defective molded plug or receptacle. Cut the wire an inch or two back from the point where it enters the molded body of the plug or receptacle. Do not try to open a molded plug or molded receptacle to repair it. Molded plugs and receptacles were not designed to be repaired.

• 7

  Separate the two halves of the extension cord and, using the wire strippers remove, 1/2 to 3/4 inches of insulation from each of the wires.

• 8

  Attach the copper colored conductor to the brass screw on the replacement device. Wrap the wire around the screw in a clockwise direction and tighten the screw down on it. Repeat this procedure for the silver wire and silver screw.

• 9

  Fill the holes made by the test probes with liquid tape.