How do I replace the end on my extension cord?

How Do I Replace the End on an Extension Cord?

To replace the end of an extension cord, cut off the damaged plug, strip the outer jacket and wires, and connect the wires to a new replacement plug following the color-coded terminals.

Always unplug the cord before starting and confirm the replacement plug matches the cord’s amperage rating.

What You’ll Need

• Replacement plug (matching amp rating)
• Wire strippers
• Utility knife
• Screwdriver
• Electrical tape (if needed)

Make sure the new plug is rated for the same amperage as your extension cord (15-amp or 20-amp).

Step-by-Step: How to Replace an Extension Cord Plug

1. Unplug the Cord

Never work on a cord that is connected to power.

2. Cut Off the Damaged End

Use wire cutters to remove the broken or worn plug.

3. Strip the Outer Jacket

Carefully remove about 1–2 inches of the outer insulation without damaging the inner wires.

4. Strip Individual Wires

Strip about ½ inch of insulation from each wire.

You will typically see:

• Black (Hot)
• White (Neutral)
• Green (Ground)

5. Connect the Wires to the New Plug

Attach wires to the correct terminals:

• Brass screw → Black (Hot)
• Silver screw → White (Neutral)
• Green screw → Green (Ground)

Tighten all screws securely.

6. Secure the Strain Relief

Most replacement plugs include a clamp to secure the cord jacket. Tighten it to prevent wire pullout.

7. Reassemble the Plug

Close the plug housing and tighten screws.

When Should You Replace Instead of Repair?

Replace the entire extension cord if:

• The cord insulation is cracked or brittle
• Multiple sections are damaged
• The cord overheats during use
• It shows signs of internal wire damage

For heavily worn cords, replacement is safer than repair.

Replacing the end of an extension cord

• Buy the appropriate type of replacement plug or socket. If the extension cord is a 3 wire type (with grounding connection), buy a 3 pronged replacement. Likewise, make sure that the replacement is rated for the same load as the cord; if you have a heavy-duty cord, ensure that the replacement is rated for heavy-duty loads.
• Cut off the broken plug or socket with the knife.
• Strip half an inch of the outer cord casing from the cable near the cut end. Be careful to cut only the outer casing and avoid damaging the interior wires.
• Strip half an inch of insulation from each of the individual wires within the casing.
• Disassemble the replacement plug or socket. Generally, replacement plugs consist of a plastic outer case that contains screw-down terminals to which the individual wires attach. Some plugs come from the store in a disassembled state, while others require unscrewing a screw or unsnapping a case to access the interior screw terminals.
• Screw the exposed extension cord wires to the terminals inside the replacement plug or socket. If your replacement plug has screw-type terminals, loop wire around the terminal and then screw it down. The green wire is the ground wire, the white wire is the neutral wire, and the black wire is the hot wire. Light-duty interior extension cords often lack the ground wire, but if a ground wire is present, be sure to connect it. Many replacement plugs come with color-coded terminal screws, making connection to the right terminal easy. If in doubt, check the wiring diagram that came with the replacement plug or socket.
• Put the plug or socket casing back together around the terminals. Depending on the exact model you have, this may require snapping a plastic case into place or screwing in a retaining screw. Make sure no bare wire is exposed.

Important Information:

Check your state and local codes before starting any project. Follow all safety precautions. Every effort has been made to ensure the accuracy and safety of this information. Neither Westlake nor any contributor can be held responsible for damages or injuries resulting from the use of the information in this document.