Chrysler Pacifica EV Charger Repair (EVSE)

The Chrysler Pacifica EV Charging Cord (aka EVSE) is challenging to repair because the case is sealed. In addition the J1772 Handle is potted and cannot be repaired. 

We recently received a Pacifica EVSE with a damaged J1772 handle (they drove away with it plugged in).  Upon inspection it looked like the J1772 cable had been pulled out of the case so to be on the safe side we decided to open the case. This EV Charger is manufactured by Lear, the same company that manufactures some Chevy and FIAT chargers. Those charger can be opened by cracking the weld on the edge of the case. That proved to be not the case.

We cut the case with a thin blade saw to just below the ridge at the base and found that one of the wires had pulled off the 1/4" quick connect spade terminal.  We reconnected the wire and viola it worked.  NOTE: Don't let the saw blade enter inside the case as you may hit some components

We glued the case together with high strength epoxy.  This was a little challenging because there was a jagged piece on the end of the case.  See photo with the white line.  Besure to cut straight across both ends.  See photos for completed repair and additional info on the fault codes.  bit.ly/Pacifica-EVSE-FaultCodes

We also installed a new J1772 handle. NOTE: Do Not use the standard dies that come with the 20 ton crimper (solder instead). The proximity switch was connected to 2 short pieces of hook up wire that were added because the wires on the switch were too short

NOTEs:
1.  All repairs include our '5 Point Safety Certifications test' and a 6 month warranty. Click here EVLAB '5 Point Safety Certification'  
2. EV BULLETIN Chrysler Pacifica EV Charger Fault Codes
3.  Here are the identifying #'s of the Chrysler Pacifica EV Charging Cord. P05062107AC, S9065010, V96555BD