Repair Apple AC Power Adapter
If the cord coming out of AC adapter shorted out.This explains how to fix an Apple AC Power Adapter that has a shorting cord. If your power adapter has a different problem, there might still be useful information here for you.
Since the cord is shorting, so must cut out the place where the short is and splice the good parts back together. Go ahead and chop the cable off now as it will just get in the way if you have to open the case.
Now comes the hard part,Once the seal is cracked, you still aren't quite home free because there's a metal shield inside that's glued to the top of the case. If you're pulling and it springs a little bit but doesn't open, get up under the shield with a screwdriver and gently separate it from the top.
The power cord itself isn't your standard two-wire cable. Instead, it's a very thin coaxial setup. The core provides the ground and the outer cage acts as a ground. In order to splice these, we first need to separate them.
Start by carefully stripping off the outer casing. Wire strippers could work here, but be careful not to cut through the ground wires. I didn't have a wire stripper, so I used a knife and my fingernails. Once the outer casing is off, separate the ground wires and strip the casing from the inner cable. There will be some thin green floss mixed in to the ground cage that provides padding and strength to the cable that you can separate out and trim off.
Now we need to get a some exposed wire on the adapter side to splice the cord on to. See that little plastic thing that the cord passes through as it enters the case? It keeps the cord from getting yanked off of the board when you pull on it. Inside the plastic thing, the cord is tied in a knot. If you can cut away the plastic thing without cutting through the cable, you can untie the knot and get a decent length of wire to work with.
Once you have the cord exposed, repeat the stripping process from earlier and splice away. To do this properly, you should probably twist the wires and then bind them with solder.
It's time to putting things together, wrap the cable in such a way as to protect both the splice point and the board connection from stress. You don't want all of your hard work to be undone by a careless yank on your cord. Once you've got everything pretty secured the way you want it, tape it up or glue it, or encase the whole thing in carbonite.
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