Anyone have their block heater cord basically melt?? Plugged mine in the other day for 3 or 4 hrs then had to run some errands. Go to unglug it and the plug was quite warm, but didnt think too much of it since hadnt used it since beginning of year. Got home plugged er back in. Next morning go out unplug and I hear a zapping sound, look and there are the wires showing, right behind the block heater plug where the wires terminate. They arced once alittle bit before I could fully unplug.

Didnt do anything differently than I ever have, don't unplug by pulling wires, always with plug it's self. I ordered new plug from Geno's, so hopefully it arrives soon. It's gettin cool out. If ya call over night lows of teens cool. haha.

 

Right behind the plug on the block heater cord is typically right where the wires break. The metal fatigues from years of flexing and twisting right there every time you plug in or unplug your block heater, as well as swaying in the wind, etc. I would guess the wires were thin and broken right there, and the resulting resistance caused the wire to heat up there when the current flowed through. A new cord should fix it right up.

 

^^X2

Mostly the swaying in the breeze. Flexing in the wind will fatigue the copper to the point of failure in even one year (from an electrician).

If you can keep your cord tucked in out of the wind when not being used, its a good idea.

Cya

 

Thanks guys, that's what I'm hoping it was. During the summer it USUALLY is tucked behind and in the bumper. What I generally do during the winter while driving is slip the plug behind the tow hook, loop plug cover over tow hook, then cover plug, so as to keep from swaying too much while driving, but allowing easy access to plug when at home.

So is a couple yrs all we can expect out of these cords, even when trying to take care of em?? Hope not. But then again, I do use it quite a bit during the winter. Sure makes starting alot easier on the truck, not to mention not having to drive 10 miles to get warm air, hahahaha. Thanks again, Scott.

 

I am getting my cord replaced next tuesday has the wires are stating to pull out of the plug dealer said it was a factory defect not molded right

 

Hopefully the dealer doesn't charge you for it. Was $40+ from a dealer out here for the 1st one I bought. My 04 didnt have a cord so had to buy it. My 06 I have now came with it ( PO must have already installed it). Through Geno's is $14. about $6 s&h. Cost me $20.90 total shipped. Piece of cake to install yourself. Course if they not chargin ya to replace and install then why not let em, lol.

 

I have a fe extra ones in the shed i believe. Not sure where I got them from but they are there. Since I run more than one heater on mine I have them all going to an Arctic leash and use that to plug into the outlet instead of an extension cord. It's just a retractable reel with a cord. Works wonderfully. Also we use the blue arctic cords and they last for a long time. All our vehicles have block heaters and such and we use a junction box with the arctic cord and I've never had to change one out.

 

For years, my job had power outlets set up for each worker. However, if you had more than one cord going to your vehicle you would get in trouble so:
These pics are from my 1986 Subaru. I used regular 12 G house wire, put a male plug on it and than silicone’d the heck out of it.
The wire than ran to a regular household electrical outlet under the hood far enough back to keep it out of the rain and slush. Depending on the weather I would sometimes plug in the block heater, battery heater, oil pan heater and a small interior heater (drilled a hole through the firewall for that one) plugged in all at the same time.
This set up was installed in 1986. The solid house wire never cared about the wind, ice or yanking that it got subjected to. It still works today.
My truck is set up the same way but is currently in CA with a tarp over it to keep the sun from baking it Wish I was with it...sigh

 

my cord replacement is covered by the warrenty and even if it was not the cord is only $15.00

 

the damage to that area of the cord can also be caused by grabbing hold of the cord to unplug it instead of grasping it by the plug.

 

Well of all the bone headed things to do. Just got back in from checking and snuggin up the injector isolators, which by the way were slightly loose, got about 1/2 turn out of the back 2 which seemed to help with the ticking sound. Anyhow, as I'm doing this I look over to the batteries and noticed the battery blankets and go "oh crap"!. Yup go look at the block heater plug, follow the cord and sure enough it splits, goes to both batteries then the block heater. Totally forgot about that when I ordered the new cord. Was thinkin of my 04 that didnt have battery blankets, just ran straight to the heater. By the way, is that a special cold weather package or would it have been aftermarket?

So, my question now is, is that a dealer only item, as I didn't see that as an option to buy from Geno's. Or would it be possible to cut the 3 pronged plug of the existing cord, cutting back into fresh wire, and wire a new 3 prong in its place?? Hate to have to buy a complete new harness and blankets just for the plug.

 

There's no reason why you couldn't solder in a new plug. Make sure you insulate the connections well.

I think that a large part of the problem with the overheating plugs is caused by corroded prongs on the plug. These brass/copper prongs spend all year exposed to the elements. Mine look terrible. The more resistance you have at this mechanical connection, the more heat generated. I sand the prongs on mine every fall and put a little dielectric grease on them. Maybe we should find a protective dummy plug to plug into it to help protect it from the elements when not in use.

 

Funny you say that, as I had cleaned up the prongs before use because of that very fact. Yeah the plug has its own cover, and I do use it, but its not weather tight fit. I'm sure moisture gets in there. Maybe cutting the female end of an extension cord off, fill with dielectric grease put the two together and use that as a cover for the off season could help eliminate some problems.