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Charge Cable Stuck

39K views 41 replies 27 participants last post by  partridge  
#1 ·
I have a 2017 XC90 T8 and I cannot remove the charge cable. I have unlocked the doors with the FOB, the oncall app, and the locks in the car and the cable will not release. The strange thing is when you use the app it seems to only unlock the trunk. When you are in the car it shows 2 lights on the real tailgate like it is unlocked so I wonder if this is somehow related. Ther only other issue is it is bitterly cold here in Canada.
Kim
 
#2 ·
Mine was VERY hard to remove in the minus 40c.

As for the app only unlocking the truck, I believe that is designed.
 
#3 ·
Did you try re-locking and then unlocking your T8? I've found if I don't unplug the cord within a few seconds of unlocking mine, it will lock the cord in so I have to lock and unlock the doors to get it to release again.
 
#4 ·
I have twice had a problem where I could not remove the cap for the charging port after travelling in extreme weather. After thawing out in my garage, I was subsequently able to remove it and charge the vehicle. So there is definitely the possibility that you have a frozen lock. I am not certain what remediation is safe to use such as pouring warm water and such. I imagine the electrical connector is designed to handle the elements including water resistance but at the same time I'd want to read that in writing from somewhere official before I tried it. Perhaps a hair dryer might work as an attempt?

Mine was VERY hard to remove in the minus 40c.

As for the app only unlocking the truck, I believe that is designed.
Yes, this is and there is no override for this method of operation that I am aware of. One must press the tailgate button after initiating the unlock process in the VOC app to unlock the side doors.
 
#5 ·
Cable Charge Stuck



I had exactly the same happen to my T8. Only it would not come out at all after hours of different ways of trying. Late for work, appts and everything else! Eventually towed into dealership and they had to force it out and replace the broken bits. Said the cable lock had jammed on. Hope this wont be a regular occurrence!
 
#6 ·
Hi folks, unfortunately, this is my first post on the forum. Enjoying the car otherwise. I recorded this issue on my cell phone to share with my dealership in hopes of resolving this problem. I thought I would share it here, too, in case this might help the forum.


From the video description:

There is a prong inside the charging port that acts as a lock to the charging cable. Cold weather seems to keep this prong from extend/recede properly, preventing users from inserting the cable to charge or remove the cable to drive away.

This particular vehicle was brought to the dealership on 12/29/17 to address this problem. Service actions S39835 and S29843 were taken and the car was picked up on 1/10/18. On 1/15/18 the problem started replicating itself again.

The weather was noticeable warmer between 1/10-1/15 with daytime temperatures exceeding 32f. The problem began replicating itself again following freezing temperatures.

In this video, user locks and unlocks the car with the remote to no avail. User also tried starting and stopping (turn knob for 7 seconds) to no avail. Viewers can see that the prong inside the charging port does not recede.
 
#9 ·
I have same issue. This is 2nd winter for my T8 and first winter issue occurred only once, and this winter it has been already 3-4 times.

But first quick solution; I disconnect the cable from wall station, get it rolled, open side window and put the rolled end of the cable inside the car. Car's side remains connected to the cars port.
Now the car can be started. There is a warning that cable is connected, but if you keep ignition swich turned on more than 7 sec, the car starts, and it can be driven.

What I have done is I have driven it to the warm garage. And after couple of hours warm up, the cable can be disconnected normally.

It seems that the problem is something to do with freezing. MOst of cases is related to the wheather, when there is first rain or wet snow, and then outside temperature gets freezing. The car is outside and next morning the cable cannot be unlocked and unpluged.

Last service I complained about the problem, but service had no solution for it. They were searching TJ's but no solution for this problem.
 
#11 ·
I have same issue. This is 2nd winter for my T8 and first winter issue occurred only once, and this winter it has been already 3-4 times.

But first quick solution; I disconnect the cable from wall station, get it rolled, open side window and put the rolled end of the cable inside the car. Car's side remains connected to the cars port.
Now the car can be started. There is a warning that cable is connected, but if you keep ignition swich turned on more than 7 sec, the car starts, and it can be driven.

What I have done is I have driven it to the warm garage. And after couple of hours warm up, the cable can be disconnected normally.

It seems that the problem is something to do with freezing. MOst of cases is related to the wheather, when there is first rain or wet snow, and then outside temperature gets freezing. The car is outside and next morning the cable cannot be unlocked and unpluged.

Last service I complained about the problem, but service had no solution for it. They were searching TJ's but no solution for this problem.
 
#16 ·
Isn't it just the difference between the more robust Type 2 (Mennekes) plug/connectors than the old Type 1 used in NA? I've not seen a special cap specifically for weather than the standard caps specifically designed for Type 1 or Type 2.
 
#14 ·
When I first got the car I had to learn the hard way about removing the J1772 connector. Once I saw that it was necessary to lock then unlock the car I have not had a problem. Obviously Southern California does not get that cold. I have never tried using the key. I typically just push on the door handle to lock and then place my hand inside the door handle to unlock. One way to get around this issue is to use a different charger. I have found that I can remove the other charger J1772 connector without having to lock and unlock the car. It does not have the same capability of being locked once positioned. I was thinking of modifying the OEM so that it can no longer be locked. I will have to see what the differences are between the Volvo unit and my other charger connectors. I will advise as to what I learn.
 
owns 2025 Volvo EX90 Ultra
#15 ·
I live in Buffalo, that was a common problem with my T8 as well.
But it wasn't just the charge cable. The mirrors would not open. The rear door latches like to freeze. The gas door and the little door for the charge plug would also freeze. Maybe they should test these cars in a cold place, like, oh, I don't know... Sweden? :facepalm:
 
#17 ·
Joined this forum because this thread helped me out of a tricky jam. Couldn't unplug charger cable on 2017 T8. The hairdryer did the trick in about 30 seconds. Thank you! Wasn't particularly cold but it got very cold this weekend so decided not to plug it in outdoors (did plug it in a parking lot garage though and no problem).

Last winter we couldn't lock the passenger doors and had to take it in for servicing to repair which took a few days in the shop.

On our last visit to put on the winter tires, they decided to do a software update. I came home that night and it disabled the charging function completely! Thought it was my cable so I went to a public charging station which didn't work either. That took 2 more days in the shop for them to repair.
 
#18 ·
Nightmare!!

Charge cable to a commercial charger (not my home charger) was stuck, 53 degrees F outside, public parking garage at work. 2.5 hours with oncall volvo who had me call my dealer that does not have a mobile unit and was at a dead end. The garage manager shut the power and cut the cable so I could drive home with the Charger gun stuck inside.

I tried open and closing and opening a 1000 times
I tried disconnecting the battery and then reconnecting, this did not help
I tried pushing it in while unlocking.
I tried opening and closing and opening in different ways, nothing helped

I had no idea what I was going to do until the manager allowed me to cut the cable after the power was off.

I can't believe there is no release cable???? Who designed this?? Why would you design it where having your car towed is impossible.
This is one of the worst design features I have seen on any car. Is this a standard in the industry? I see on you tube Tesla has a release cable.
 
#21 ·
Charge cable to a commercial charger (not my home charger) was stuck, 53 degrees F outside, public parking garage at work. 2.5 hours with oncall volvo who had me call my dealer that does not have a mobile unit and was at a dead end. The garage manager shut the power and cut the cable so I could drive home with the Charger gun stuck inside.

I tried open and closing and opening a 1000 times
I tried disconnecting the battery and then reconnecting, this did not help
I tried pushing it in while unlocking.
I tried opening and closing and opening in different ways, nothing helped

I had no idea what I was going to do until the manager allowed me to cut the cable after the power was off.

I can't believe there is no release cable???? Who designed this?? Why would you design it where having your car towed is impossible.
This is one of the worst design features I have seen on any car. Is this a standard in the industry? I see on you tube Tesla has a release cable.
I guess there wasn't a hairdryer available.
 
#25 ·
I had this happen to my 2017. They had to pretty much replace the entire charging connector assembly.

Major pain in the rear. Imagine missing work because you can’t get your car unplugged from the wall. Almost happened a few times.


Sent from my iPhone using Tapatalk
 
#26 ·
So I now understand how the locking mechanism works and clearly the handle (with the cord sliced off last evening so I could drive home since you can override the system by holding the On switch for 7 seconds) was broken so that the plastic piece on the handle side got jammed against the pin and the pin would not fully retract. I took a screwdriver and was able to first push the plastic locking piece on the handle side down to let the pin retract when I unlocked the door and then pushed it up to release it. The button does not move this piece and clearly the handle was the issue.

This makes me nervous to ever plug it into a public place again. I will always carry from now on a screwdriver.

I think I am going to get the extension cord for EV Chargers so the public garage at work charger can plug into that. I see one on Amazon for $170 PRIMECOM 14 Feet EV Charging Cable Extension Cord 32A J1772 EV Charger Extension Cable 14ft (32Amps)



Unless someone knows of a pass-thru adapter that I can plug into the car and the public charger into that. I see adapters for tesla charger to EV J1772. I do not see one for my needs. I guess I will buy the EV extender

Realize if some one at a public charger drops the handle and it breaks than this can happen to anyone. I will always make sure the button and lock mechanism works before doing anything.
 
#27 ·
Haven't experienced this problem myself thankfully. If it were to happen to me in a public parking area, I think the best course of action would be something like a screwdriver or scratch awl. Push in on the lock pin to see if you can make it budge. Maybe tap the end of the screwdriver with a hammer, especially if you suspect ice is the issue. Aside from that I'm not sure. One could physically break the lock, but then you might be facing a constant cable connected warning and having to hold the start switch every time you drive. And you no longer have a cable lock for public parking.
 
#28 ·
So the EV Charger cable extension cord arrived and now I plug that into my car and the public parking garage end into the extension cord that does not lock. Worst case scenario, my extension cord gets locked in my car and I simply unplug it from the charging station and put it into my window to take to the dealer. I can't get trapped in a garage again with no one to call.
 
#29 ·
For anyone having similar issue, I (kind of) found a solution (after 2 charge port replacements), this only applies to situation where the locking mechanism is frozen due to cold weather. If using turbocord. it is possible to force the charging connector out by pushing the charging handle downward while pressing the release button on the J1772 handle. If it's really cold, then force to turn the car on and start the ICE by holding the start knob for 7 seconds then put the car in charge mode (or AWD/Power/Off-road drive mode) to warm up the engine bay. This will help to thaw the vehicle side connector to some extend. The situation demonstrated in the video above will cause a trouble code to set in the Onboard Charging Module, dealer should see it. Also it is possible to capture a snapshot using "send vehicle data", dealer can the latest data sent from your car in VIDA under "vehicle health", it should show all the DTCs at the time you sent the data. Hope this helps.
 
#30 ·
I have a 2020 XC90 T8. It rained and froze, could not pull it out. Used an air dryer and even some warm water, would not budge. Could not start the car either. Finally called Volvo onCall , they recommended locking the car twice the key fob and unlocking it twice with the fob. It worked, the cable released.
Philippe
 
#31 ·
I'm having the same problem with my charger on my 2019 XC90 T8. When I unlock the car, everything unlocks, but occasionally the charger does not. I live in Southern California, so it's not the cold! Suggestions? I'm afraid of charging away from home now, for fear I will not be able to release my car from the charging station!