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How to Repair a Frayed Apple Lightning Charger

Written By: Kalynn Copeharve (and 5 other contributors)
  • Comments: 9
  • Favorites: 4
  • Completions: 4

Difficulty

Easy

Steps

8

Time Required

10 - 15 minutes

Sections

1

Flags

0

Introduction

Apple charging cables, such as the Lightning to USB Cable, are easily prone to fraying. Most commonly, this fraying occurs from device usage while charging. Cables may be subject to extreme angles while charging which causes the outer coating to loosen, tear, and ultimately expose its wiring. Exposed cable wiring is hazardous to both the device and its user, and may cause electrical shorting or even shocking. Repairing a frayed cable with heat shrink is an easy and inexpensive alternative that allows the user to safely charge their device.

  1. Locate the frayed or exposed area of the Lightning cable. It may be necessary to further expose frayed areas for the repair. With your fingers, gently pull the cable wiring from its outer coating until they separate.

    • Locate the frayed or exposed area of the Lightning cable.

    • It may be necessary to further expose frayed areas for the repair. With your fingers, gently pull the cable wiring from its outer coating until they separate.

    Edit

  2. Remove the excess coating from the frayed area by cutting it off with scissors. Remove the excess coating from the frayed area by cutting it off with scissors.

    • Remove the excess coating from the frayed area by cutting it off with scissors.

    Edit

  3. Measure the approximate length of heat shrink needed to cover the frayed or exposed area. While cutting, keep the length of the heat shrink longer than the length of the frayed or damaged area. While cutting, keep the length of the heat shrink longer than the length of the frayed or damaged area.

    • Measure the approximate length of heat shrink needed to cover the frayed or exposed area.

    • While cutting, keep the length of the heat shrink longer than the length of the frayed or damaged area.

    Edit

  5. Slide the heat shrink over the wire so that it covers the frayed or exposed area. The 1/4" heat shrink used is not large enough to slide over the connector near the fraying. It may be necessary to slide the heat shrink over the opposite end of the charger. The 1/4" heat shrink used is not large enough to slide over the connector near the fraying. It may be necessary to slide the heat shrink over the opposite end of the charger.

    • Slide the heat shrink over the wire so that it covers the frayed or exposed area.

    • The 1/4" heat shrink used is not large enough to slide over the connector near the fraying. It may be necessary to slide the heat shrink over the opposite end of the charger.

    Edit

  6. Warm up the hair dryer by turning it on the highest heat setting. Warm up the hair dryer by turning it on the highest heat setting.

    • Warm up the hair dryer by turning it on the highest heat setting.

    Edit

  7. Apply heat to the heat shrink. While heating, keep the hair dryer in motion. Applying heat for too long in one location will result in overheating. Overheating may further damage the frayed or exposed wire underneath, and it can even melt the heat shrink itself.

    • Apply heat to the heat shrink.

    • While heating, keep the hair dryer in motion. Applying heat for too long in one location will result in overheating. Overheating may further damage the frayed or exposed wire underneath, and it can even melt the heat shrink itself.

    Edit

  8. Allow the heat shrink to dry for two minutes.

    • Allow the heat shrink to dry for two minutes.

    Edit

  9. Test the fit by flexing the cable in different directions. If the fit is loose, apply an additional layer of heat shrink by recompleting Steps 3-7.

    • Test the fit by flexing the cable in different directions.

    • If the fit is loose, apply an additional layer of heat shrink by recompleting Steps 3-7.

    Edit
Conclusion

To reassemble your device, follow these instructions in reverse order.

4 other people completed this guide.

Author

with 5 other contributors

Kalynn Copeharve

Member since: 09/30/2016

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Missouri Western, Team 1-3, Adkins Fall 2016 Member of Missouri Western, Team 1-3, Adkins Fall 2016

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4 Guides authored

7 Comments

Thank you for taking the time to post your pictures and the steps to repair a lightening cord. I plan to do this repair, and also, apply heat shrink to the other end BEFORE that one frays. Thanks!!

craig.eden - Reply

I have cables that do not work anymore due to the fraying at the lightning port end. Are there instructions on how to fix this?

Christine Lucas - Reply

The wiring is too intricate, Christine. It’s not worth the time it would take, IMO.

Dave -

Kills me as I recently fixed 3 separate lighting cables at the power converter end, but took no pictures! You have to razor the seam around the outside of the case, split the case apart by pulling out with pliers in the cord-wrap flap area (careful don’t split it) and then attach a new cord to the solder spots on the circuit board, or just to the wire stubs. Best to just order a replacement cord as these include the little stopper that fits into the case between the halves. If you’re good at solder-joining cables you can just do this and shrink-wrap ‘em, but I prefer to use a little crimp joiner, and then fill the crimp with solder before sliding the shrink-wrap down over it. It’s tricky because the join has to fit a small space inside the case. You can get replacement cords at AliExpress. I use duct-tape to tightly close the case in case of more repairs.

https://nl.aliexpress.com/wholesale?catI...

Atticus Mullikin -

Does this work with plastic straws instead of heat shrink?

joris van de noort - Reply

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