Yellow Charge Cable Repair

The OEM 120 VAC charge cable for the Tesla Roadster uses a Ground Fault Interrupter (GFI) 15 A plug. Over time, the stranded conductors inside the plug compress and loosen, raising resistance and heat. That heat damages the GFI electronics, causing intermittent charging, nuisance trips, or total failure. These plug failures are among the most common causes of
bricked Roadsters (Dead battery packs left uncharged).

What’s going on?

• Shared/daisy-chained outlets: Many 120 V circuits aren’t dedicated. Continuous 15 A draw increases voltage drop and heat at the plug.
• Low-tech GFI board: Heat browns the PCB and weakens solder joints and the relay/triac, degrading ground-fault sensing.
• No clean failure: Compromised plugs often “limp,” delivering sub-standard current with intermittent trips—then quit when the car is unattended (storage, vacation).

We remove the Ground Fault Interrupter plug and re-terminate the stranded input conductors for a longer-lasting, lower-resistance connection.

• Eliminates the failure-prone GFI module in the cord-end.
• Stabilizes charging current and reduces nuisance trips.
• Improves durability of the cord termination.