Ford told me to pound sand in response to my request to replace my second level one EVSE convenience cord.
Since I found a used Level 2 Ebusbar NEMA 10-30 on ebay that has worked well for over a month, I decided to try to replace the plug on the level one as numerous posters have suggested.
Polishing the plug prongs did nothing, and placing an icepack on the plug was a tedious solution that only delayed the inevitable charge fault an hour or two, so I wanted to get the cord back to working order by swapping the plug.
There has been some discussion as to whether or not a temp sensor exists within the molded rubber 3 prong plug. Upon slicing the plug in half and dissecting the molded rubber between the three prong I found that there are 2 extra wires 22 AWG in blue and brown in addition to the 16 AWG Black, White and Green.
I would like to upload the photos of the wiring and the dissected ends of the 22 AWG brown and blue wire ends with soldered connections which look to be to two halves of a soldered on wishbone temp sensor, but I cannot upload photos through the gallery anymore despite having current flash and loading smaller MB photos. I apologize. I have pictures to illustrate this and a couple other threads, but only get a message that a "server error occurred during upload." So instead of adding photos where appropriate I'll add em below. Maybe someone can figure out if it is a sensor or just soldered together or some other configuration.
I have failed to fix the issue after three different wiring attempts with the blue and brown 22 AWG wires (in addition to the 16 AWG Black- Hot, White- Neutral and Green -Earth/Ground.)
Each of my wiring attempts have caused the EVSE to fault instantly upon plugging into outlet without being plugged into vehicle charge port.
I have tried 1)capping the ends of the blue and brown 22AWG, 2) wiring them together and 3) wiring the brown to the hot prong and the blue to the neutral. All attempts to get the EVSE going have failed. Perhaps there is a mechanical defect in the new Leviton Heavy Duty Male plug causing a fault, but it seems unlikely.
I was unable to excavate the delicate wiring and possible tiny soldered sensor in one piece out of the solid molded rubber and unfortunately can't upload the pics to gallery so someone with better knowledge could more easily troubleshoot. I don't know where the soldered ends were connected by very delicate wire which may have been a wishbone shaped ambient temp sensor connected to both blue and brown wire. The blue and brown may need an ambient temp sensor soldered on between the two, or they need that in addition to being soldered to hot and neutral.
The blue and brown wires could also have been soldered separately to the hot and neutral prongs or both the sensor and prongs. I dug out two soldered wire ends (blue and brown) and two fine solder wire leads to what could be two halves (2mm each) of the temp sensor. The picture below only shows one of the soldered leads (brown), the blue soldered end got lost, but was the same thing - a wire tip with solder.
I thought I recalled that someone had actually changed a plug on the forum, but do not recall mention of the brown or blue leads.
JZ suggested that soldering them together may work, but I am not sure how that would be different than wiring them. Obviously without the sensor their is no failsafe. That is ok if I can get the thing to charge. It will mainly be used outdoors as a backup on an extension when away from the home, but also if my level 2 EVSE starts acting up.
Should I should try to purchase a sensor from a local electronics store and solder it on or what is the next step?
Any help would be greatly appreciated. Thanks.