Introduction

Sometimes the cable starts peeling just at that place where it meets the AC Adapter. I've met too many people that throw away their chargers because of this. It takes time and patience but repair is possible!

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  • Nasty cut.

One option is to cut the protruding plastic. Just be careful not to cut the wires inside as these will be soldered to the cable. If this does not work, then you can proceed to opening the casing. I recommend this if you are hesitant to violate the integrity of your adapter.

marcellus124 - Reply

Image 1/1:
  • Unplug your AC power cord.

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Image 1/3: You will have to cut through that plastic, go all the way around following that small space with your knife. Image 2/3: This will take a while, you have to cut the plastic from all the 4 sides. You will notice when you have cut through most of it. Image 3/3: Be careful with the side shown in the last picture. There are a couple of components that might be cut in the process.
  • Look at the line that goes though the charger. This is all glued with some super adhesive that prevents you from just taking it apart.

  • You will have to cut through that plastic, go all the way around following that small space with your knife.

  • This will take a while, you have to cut the plastic from all the 4 sides. You will notice when you have cut through most of it.

  • Be careful with the side shown in the last picture. There are a couple of components that might be cut in the process.

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Image 1/3: Once you have separated all sides with the screw driver, it still wont come off. This thing is glued to all sides of the plastic. Image 2/3: Insert the screwdriver into the top part of the charger and carefully separate the foil from the plastic enclosure. Be careful as to not rip off the foil from the inner part of the charger. Image 3/3: Insert the screwdriver into the top part of the charger and carefully separate the foil from the plastic enclosure. Be careful as to not rip off the foil from the inner part of the charger.
  • With a flat headed screwdriver start separating both plastic faces from the charger. You need to use a little force to do this.

  • Once you have separated all sides with the screw driver, it still wont come off. This thing is glued to all sides of the plastic.

  • Insert the screwdriver into the top part of the charger and carefully separate the foil from the plastic enclosure. Be careful as to not rip off the foil from the inner part of the charger.

A few note's to make it look like new! And without damaging the outside.

Tip1. Flip up the bunny ears and use the back of a lighter (or something else plastic that fits) between the gap and twist it open on both sides.

Tip2. Use a small drill to clean out the rubber cable guide so u can re use it.

Tip3. Use super glue and clamp the charger long enough for the glue to dry. (don't rush it!)

peter van der Leij - Reply

Mine frayed at the computer end. Do you have any instructions for repairing that end?

Jason Smeed - Reply

I used a C ring pliers between the gap to pop it open. Refers to Tip 1

Chaozhouzi Chaozhouzi - Reply

Image 1/3: Use the screwdriver to loosen up the adhesive on both sides of the power connector. Image 2/3: Insert the screwdriver on the remaining face of the plastic enclosure and carefully loosen up the rest of the adhesive. Image 3/3: Insert the screwdriver on the remaining face of the plastic enclosure and carefully loosen up the rest of the adhesive.
  • In this step I already took off one face of the plastic enclosure.

  • Use the screwdriver to loosen up the adhesive on both sides of the power connector.

  • Insert the screwdriver on the remaining face of the plastic enclosure and carefully loosen up the rest of the adhesive.

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Image 1/1:
  • You should end up with this block. Put away the plastic enclosure.

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Image 1/3: Cut the cables as near as you can to the plastic piece. Image 2/3: Cut the cables as near as you can to the plastic piece. Image 3/3: Cut the cables as near as you can to the plastic piece.
  • Grab the small plastic piece that attaches the cables to the AC charger.

  • Cut the cables as near as you can to the plastic piece.

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Image 1/1:
  • Peel the plastic off the cable with a knife or a wire stripper.

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Image 1/3: Untangle the outer wire to reveal the white cable inside. Image 2/3: Twirl up nicely the outer wire and peel a small bit of the white cable to join the to the AC charger. Image 3/3: Twirl up nicely the outer wire and peel a small bit of the white cable to join the to the AC charger.
  • Take the cable that connects to your mac book and carefully peel it off with a knife or a wire stripper.

  • Untangle the outer wire to reveal the white cable inside.

  • Twirl up nicely the outer wire and peel a small bit of the white cable to join the to the AC charger.

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Image 1/3: Remember that the white wire from the AC adapter NEEDS to be soldered to the white wire from the cable that comes from the MacBook connector. Image 2/3: The black insulated cover tube on the cable is to isolate the cable later, you can use heat to shrink it. Image 3/3: The last pic shows the black insulated cover tube, you can cut it up to fit the length you need.
  • Join both white cable wires and solder them together.

  • Remember that the white wire from the AC adapter NEEDS to be soldered to the white wire from the cable that comes from the MacBook connector.

  • The black insulated cover tube on the cable is to isolate the cable later, you can use heat to shrink it.

  • The last pic shows the black insulated cover tube, you can cut it up to fit the length you need.

  • It is very important to isolate both wires, they cannot touch each other or else they will short circuit (in other words: Kaboom!).

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Image 1/3: Isolate that wire. You don't need to cover up the whole extension of the outer wire, just enough so that it won't touch the white cable or the circuit board of the AC adapter. Image 2/3: You can use the black rubber tube or  electrical tape. If you use the black tube try to keep it as far away as possible when soldering to prevent it from shrinking before you cover the wire. Image 3/3: You can use the black rubber tube or  electrical tape. If you use the black tube try to keep it as far away as possible when soldering to prevent it from shrinking before you cover the wire.
  • Proceed to solder the black cable from the AC charger to the outer wire of your Macbook connector.

  • Isolate that wire. You don't need to cover up the whole extension of the outer wire, just enough so that it won't touch the white cable or the circuit board of the AC adapter.

  • You can use the black rubber tube or electrical tape. If you use the black tube try to keep it as far away as possible when soldering to prevent it from shrinking before you cover the wire.

Which solder or soldering Iron you guys used? I am trying to do everything with my Goot 40W soldering iron and nothing happens:-

1. I tried to join black wire but my 60/40 solder won't stick to it at all.

2. i tried to replace the whole cable with a new cable bought from Amazon and I am unable to get the joint on PCB to get melted.

Please help!!!!

varun_ag - Reply

Image 1/3: Join them together with electrical tape as to form one cable and place the AC charger in one of the faces of the plastic enclosure. Image 2/3: White electrical tape makes this fix look nicer. Image 3/3: Take 3 small zip ties and tie them around the cable to stop it from being pulled out of the plastic enclosure.
  • Cover up with electrical tape the rest the white and black/outer cable you just soldered.

  • Join them together with electrical tape as to form one cable and place the AC charger in one of the faces of the plastic enclosure.

  • White electrical tape makes this fix look nicer.

  • Take 3 small zip ties and tie them around the cable to stop it from being pulled out of the plastic enclosure.

Very useful instruction. I almost bought an expensive replacement. Thanks! I also tied a knot from the wire before soldering. The knot was small enough to fit in the housing where the "round piece" was. The knot will help reduce the chance that the wires being yanked out if you accidentally trip over it.

hiennguyen - Reply

This guide was great, thank you for saving me the costs of a new charger. I found it was possible to use the original plastic attachment between the cable and the ac adapter for the repair.

I first used a 3mm drill bit and removed the bit of cable in the plastic/rubber piece. I then used a 4mm bit to open the hole further and soften the rubber part of the piece. I then threaded the cable through the piece before soldering in step 10. It makes the fix look more like the charger in the beginning and also prevents the wires being pulled through the opening.

kilian - Reply

Image 1/1: Don't forget the plastic tabs that let you wrap your cable on the charger... Even though those are the main cause for your cable tearing up! I usually choose to leave them out or glue them to the enclosure to prevent the cable breaking again.
  • Put small bits of super glue on the borders of the enclosures. Place the other face of the plastic enclosure and close up the AC charger.

  • Don't forget the plastic tabs that let you wrap your cable on the charger... Even though those are the main cause for your cable tearing up! I usually choose to leave them out or glue them to the enclosure to prevent the cable breaking again.

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Image 1/2: Some people prefer to use only super glue because it looks nicer but zip ties make it safer. If you like it better without the zip ties, take them out after a few hours after the super glue has bonded completely. Image 2/2: Some people prefer to use only super glue because it looks nicer but zip ties make it safer. If you like it better without the zip ties, take them out after a few hours after the super glue has bonded completely.
  • Tie 4 large zip ties to close up the enclosure, 2 on each side.

  • Some people prefer to use only super glue because it looks nicer but zip ties make it safer. If you like it better without the zip ties, take them out after a few hours after the super glue has bonded completely.

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Image 1/2: Don't use too much, just enough so that there is no opening from the outside. Image 2/2: Don't use too much, just enough so that there is no opening from the outside.
  • Use a glue gun to close up the gap that remains.

  • Don't use too much, just enough so that there is no opening from the outside.

instead of glue, put liquid silicon for bathrooms, that's easier to remove if you need to / however to give a form, when not yet dry, some difficulties ( it sticks on fingers )

Christophe Siekierkowski - Reply

I use my macbook at school and I'm on my 4th charger :( https://vidd.me/SuY

Tess - Reply

instead of glue i suggest Sugru for the finishing touch.. https://sugru.com/

sebastianfrith - Reply

Instead of using the stub wires I soldered the cable ends directly to the PCB. Although it worked I cannot recommend it as the PCB is easily damaged when removing the pins to which the wires are connected. Pulling off a PCB track would step up the difficulty of repair considerably....

bommels - Reply

Finish Line

150 other people completed this guide.

Angela Penaherrera

Member since: 05/06/2013

11,543 Reputation

11 Guides authored

28 Comments

Some tips:

* There is a better way to open the enclosure without damaging the edge: using a pliers to push the two sides apart where the bunny ears lift up (google for videos).

* The cable can actually be threaded through the rubber/plastic grommet if you have the patience to remove the broken cable from it and make the two small holes bigger with a drill bit. This can be frustrating but is the only way to keep the original appearance. Be sure to leave enough cable after the grommet for soldering.

* Thin (2-3mm) heat shrink is a good way to insulate the exposed wire after threading it through the grommet.

* If you trust your soldering skills, consider de-soldering the old cables from the terminals.

* Applying a little super glue along the edge and clamping for a few hours is all that is needed to keep it closed permanently.

don - Reply

Thanks for the tips! If you have pictures of the processes please feel free to modify this guide (especially the opening of the enclosure!) ^__^

* I have seen that in some tutorials and I wanted to to drill a hole through the rubber plastic grommet but didn't have a drill at my office =(

* I did consider de-soldering the old cables but that involved de-soldering other components that are attached to copper plates to get to those terminals. In earlier versions of the AC Adapter this can be done with not so much trouble.

I really appreciate your feedback! Thanks!

Angela Penaherrera -

I didn't try that... We actually ended up just heating it to soften the plastic and that worked, wouldn't advise it though

deavisdude -

Is it possible to remove the cord entirely from the circuit board and solder new replacement? I have ordered a replacement and I wonder if its safe to do so? Thank you for your prompt response!

Shawn - Reply

Yes it is possible. Depending on the model of your charger you might need to de-solder some copper plates on the bottom of the circuit board in order to be able to reach the spots for soldering the replacement cable.

Angela Penaherrera -

I found out a more elegant way of disassembling this thing, and posted a guide here:

Restoring Apple AC Adapter Broken Cable

Darie H - Reply

Hi! thanks for sharing! I used that guide on another AC charger and was so much easier to take apart!

Angela Penaherrera -

this was so helpful I did a variation of what was described and I'm very happy!!!

jdebrofsky - Reply

This worked great! It literally took me 15 minutes using a dremel tool.

stevenmcconnon - Reply

I managed to reuse original wire hose instead of tape and hot melt glue.

That required some lengthy cleanup of remainders of the wire and some knife work but the charger looks almost as new.

Oleg Urzhumtsev - Reply

Muchas gracias, muy buen material de ayuda

Javito - Reply

Hello i did it and when i plug it into the power my MacBook only charge for like 5 seconds. Can anyone help please?

Thanks

Sarel Prinsloo - Reply

omh my &&^& this is so %#*@ &&^&^$^ helpful thanks a lot man &&^&^$^ thanks

sai sorm - Reply

10 min start to finnish just needed info on opening the case thanks work like new.

bullfrog8910 - Reply

%#*@! Thank you so much for this. My charger is up and running. ;) Cheers!

Ankit Yes - Reply

Mine does't work when I put both sides of the casing back on. Works fine with only one side. I tested the soldered contacts - they are fine. I did rip off some of the tin foil by accident thoug. Any clues?

Simon Schneider - Reply

1.5 hours and very straight forward. I would reiterate the importance of making sure ADAPTER MUST BE UNPLUGGED!! before attempting to remove casing or anything further. I feel like electrical hazards were overlooked in the tutorial.

Joshua - Reply

Joshua, sorry to say that, but do you really think anybody in his right mind would attempt to remove the adapter casing before unplugging the adapter? Is such a thing even possible? You gotta give people some credit. I doubt such morons even exist. If they do, maybe it's best they don't reproduce. Darwin Awards, you know?

Anyway.

I'm attempting to do the repair as well. Just to say, I had two adapters I wanted to repair, one was a 85W: almost impossible to open. It took ages. I cut it with the knife, all around, then took some pliers to it to force it open, I ended up cracking the case. All that before realizing my soldering iron was toast. I was planning on borrowing one so I didn't give up. I took the other adapter, a 45W, this time, no knife, I went directly with the pliers, it opened directly, no damage. I think there are a lot of different versions of the adapters. Depending on the one you get, you might be lucky.

Both of mine, I need to unsolder to open any further. I'll come back with more news.

nessdufrat -

Thanks Angela - a very useful guide. I used a fine toothed saw to open up the power supply and a drill to scour out the plastic stopper. White duck tape to keep it closed after I glued it back again. Sure beats buying a new one! Time spent - 45 minutes.

cshop - Reply

Hello, I recently had the same problem and successfully fixed it using this guide so thanks. However, I'm curios, if the adapter does for some reason short circuit, what's the worst that could happen? Will the damage be in my macbook only or is there a risk that I might damage the whole wirings in the office?

DevMan - Reply

Inspired by this guide. I fixed mine without opening the adapter. I hacksawed the upper part (protruding from the adapter) of the plastic piece connecting the cable to the adapter. Then reconnected the wires as described here (without opening case).

marcellus124 - Reply

Used the pliers method to open. I unsoldered the remaining cable at the supply and resoldered the cable directly to the power supply board. To protect the cable from future damage, I added a strain relief. I drilled a 2 holes in the side of the case, looped a zip tie through, then strapped the cable to the side of the case. Oriented cable so that it lies along the side of the supply rather than sticking straight out. It is possible to use the plug prongs as a guide to wrap the cable around the case. I did not bother putting the bunny ears back on and closed up the supply with tape.

tkarches - Reply

The design of the Apple adapters is such that they will all eventually break with how the cable is attached. If you leave some slack in the cable before wrapping the cable around the ears, it will last much longer.

tkarches - Reply

I think mine must have shorted out before dissassembly. I replaced the charge cable with a new one but the charger must have been damaged when it shorted. Is there like a safety component in the charger that stops charging in the event of a short, and maybe can be replaced??? Can anyone advise??

Eduardo - Reply

Mine process was just fine, but I have one problem. That thing gets unbearably hot now :( Is it because of extra resistance ?

Dominykas Sribikė - Reply

Opening the case was a B!tcH. One thing I wish I knew ahead of time was more about the basics of soldering. I chewed through a lot of wire just to practice to get the connection right before I ran out of slack and solder too close to the adapter. Buying a cheapo soldering iron (60-watt) was a waste of time. Buy (or rent) an 100-watt so that you can heat the connection up BELOW the wire. Then you can bring in solder from above so that it melts into the wire!! Just need an hot enough gun.

Sean Sumwalt - Reply

I had a frayed cord, with the conducting metal wire completely detached from the rest of the conducting wire (below the insulating material). If that's the case for you, you can peal off the insulating layer from an old iPhone charger, remove the conducting wire and use it to join the two dead ends on the cord of your macbook charger. Apply some electrical tape on top of it and you now have a working charger!

al 4515 - Reply

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