Having a broken cord on your hair dryer can be extremely frustrating. Not being able to use your hair dryer when you need it most is a huge inconvenience. Fortunately, with the right tools and some basic technical knowledge, fixing a broken cord is an easy DIY project.
This step-by-step guide will walk you through everything you need to know to safely and efficiently repair the power cord on your hair dryer.
Necessary Tools and Materials
Before getting started, make sure you have the following tools and materials on hand:
- Screwdriver (flathead and Philips head)
- Wire cutters/strippers
- Electrical tape
- Heat shrink tubing
- Replacement power cord
- Wire connectors
- Multimeter (optional)
Screwdrivers
You’ll need both a flathead and Philips head screwdriver to take apart your hair dryer and access the broken power cord. Make sure you use the properly sized screwdriver head to avoid stripping the screws.
Wire Cutters/Strippers
High quality wire cutters/strippers are necessary to cleanly cut away the broken section of the power cord and strip the insulation off the individual wires inside.
Electrical Tape
Electrical tape will be used to wrap and insulate wire connections.
Heat Shrink Tubing
Heat shrink tubing reinforces wire connections and prevents shorts/fires. Simply slide it over your connections and apply heat to shrink it tight.
Replacement Power Cord
You’ll need to purchase a replacement power cord specifically designed for hair dryers. Match the wire gauge, length, and number of conductors.
Wire Connectors
Use wire connectors (sometimes called wire nuts) to connect individual wires together. Make sure you get the properly sized connectors.
Multimeter (Optional)
A multimeter allows you to test connections to make sure wires are connected properly. It can detect shorts and other problems.
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Step 1: Unplug the Hair Dryer
Before doing any work on the hair dryer, make sure it is completely disconnected from any power source. Not only does this make it safer to handle, but it prevents accidental shorts which could damage the dryer further.
- Unplug the cord from the outlet
- If using a detachable cord, disconnect it from the dryer
- Double check that it cannot possibly be plugged in during repairs
Step 2: Disassemble the Hair Dryer
Most hair dryers consist of two main halves–a back half that houses the fan and heating element and a front half with all the controls. You’ll need to separate these halves to access the power wires.
- Use a screwdriver to remove all external screws. Make note of where each screw goes.
- Carefully pry apart the two halves of the plastic housing. Internal locking tabs may hold it together tightly.
- If needed, trace where the power wires lead from the cord through the dryer and disconnect them.
- Thoroughly inspect the internal parts/connections for any damage before continuing.
Step 3: Cut Away the Damaged Section of Cord
Examine the power cord closely to find the exact location of the damage. When you have identified the problem area, you can cut it out.
- Mark the cord about 1/2″ on either side of the damaged spot.
- Use your wire cutters to cleanly cut all the way through the cord at both marks.
- Make sure you leave enough spare cord coming from the dryer to be able to make connections later.
Step 4: Strip Away Insulation from Wire Ends
With the damaged cord cut out, you now need to expose the inner copper wires on the newly cut wire ends.
- Use the wire strippers to remove 3/8″ – 1/2″ of insulation from each wire end, taking care not to nick the copper.
- Carefully twist the strands of copper together tightly.
- Repeat on both cord ends until all wires are stripped and twisted together.
Step 5: Prepare the New Replacement Cord
Your new replacement power cord needs to have insulation removed on each wire end as well.
- Mark 1/2” from each wire end of the new cord.
- Strip away 3/8” – 1/2″ of insulation at the marks, again taking care not to cut the inner copper.
- Twist all wire strands tightly together.
Step 6: Connect Corresponding Wires
With all wire ends prepped and ready, you can connect the replacement cord to the original dryer wires.
- Match up wires of same colors from the old cord to new cord. Typically black wire = hot, white wire = neutral, green wire = ground.
- Twist corresponding wire ends together securely using pliers.
- Use appropriately sized wire connectors to join the matched wires. Twist connectors tightly until no copper is exposed.
Repeat process until all wires are connected from original dryer cord to new replacement cord.
Step 7: Insulate Wire Connections
While the wire connectors form a secure connection, additional insulation should be added as a protective measure.
- Begin wrapping electrical tape around each individual wire connector. Leave half an inch of tape hanging over each end.
- After all connectors are taped, gather them together and tightly wrap tape around the entire group of wires & connectors. This keeps everything neat and prevents shorts.
- For even greater insulation, heat shrink wrap can now be placed over the connections and heated until it conforms tightly.
Step 8: Reinstall Cord and Reassemble Dryer
With a solid, insulated connection made, all that remains is to reinstall the new cord and reassemble the dryer housing.
- Trace wires back along original path, securing as needed with zip ties or tape.
- Ensure no wires will be crimped or frayed by contact with internal components.
- Rejoin the two halves, taking care to align components properly.
- Replace any rubber gaskets that were removed.
- Insert and tighten all housing screws. Do not over tighten.
- If using a detachable cord, connect it securely in place.
Step 9: Inspect Repair and Test Operation
Prior to considering the repair complete, the hair dryer needs to be plugged in and thoroughly tested.
- Visually inspect cord connections for any exposed wire. All connections should be fully insulated.
- Plug dryer into outlet and test each heat/power setting for proper operation.
- Verify cord is not excessively hot, as this indicates faulty wiring.
- If multimeter is available, check continuity of wires and ensure no shorts are present from line to ground.
- Use dryer as normal, bending cord at different angles to ensure wiring remains intact inside.
Assuming proper function has been confirmed, the hair dryer can be put back into regular use. The repaired cord should now provide many more years of service.
Troubleshooting Tips for Hair Dryer Cord Repairs
While the repair process itself is relatively straightforward for most basic cord issues, problems can arise both during the repair and after. Here is some guidance on troubleshooting tricky situations with your hair dryer.
Dryer Still Not Working Right After Cord Replacement
If your newly repaired hair dryer fails to power on, gets hot, trips breakers, or has other operational issues, the problem may not be with the cord repair itself.
Possible explanations include:
- Faulty power switch – If dryer won’t turn on at all, issue may be worn switch unrelated to cord.
- Short circuit – Damaged internal wiring could be shorting, preventing proper function or even causing fires.
- Heating element failure – The heating coil itself could have broken open or degraded over time.
- Impaired fan operation – Reduced air flow over heating element can cause overheating.
Thoroughly checking dryer components will be required to determine root cause of continued failure after cord replacement.
New Cord Gets Very Hot in Use
While expected to get moderately warm during use, an excessively hot cord points to faulty wiring or inadequate wire gauge.
Potential solutions:
- Check wire connectors – If loose, resistance goes up, as does heat. Retape and confirm connections are tight.
- Ensure matched wire colors – Connecting hot wire to neutral or ground will overheat cord.
- Cord wire gauge too small – If original dryer had #14 gauge wire, replacing with #16 or smaller gauge could overheat, especially on high heat setting use.
Replacement Cord Ultimately Fails Again
When repaired cord works initially but then fails again down the road, the most likely explanation is flex fatigue. Constant manipulation of the cord eventually causes internal wire breakage. Steps to improve cord longevity:
- Consider adding protective sleeve over repaired section to reduce flexing.
- Secure cord to dryer with ties/clamps to provide strain relief.
- When coiling cord for storage, gently loop wide vs. sharply twisting – this fatigues wire over time.
- Replace again with a premium, flexible cord designed for repeated use.
Safety Precautions When Working with Electrical Devices
It’s worth remembering proper safety protocol when digging into repairing any device powered by electricity, including hair dryers. Accidental shocks or shorts can endanger both you and the appliance itself if proper care isn’t taken.
- Always confirm dryer is unplugged prior starting work.
- Check wires with non-contact voltage tester before handling.
- Do NOT plug in device after repairs until all connections securely insulated.
- When powered up post-repair, keep hands and conductive tools away from circuitry.
- Consider wearing insulating gloves when testing questionable wiring.
- If uncertain about any aspect of electrical procedures, consult professional.
By remembering these guidelines and following safe handling procedures throughout the repair process, you’ll avoid personal risk and correctly fix your broken hair dryer.
Conclusion
As we’ve gone over in detail above, repairing a damaged power cord on your hair dryer is a very achievable task for most do-it-yourselfers. As long as you have the proper tools, replacement cord, and follow effective wiring procedures, you can often give your broken dryer new life very cost effectively.
While the basic process may seem intimidating if you’ve never attempted cord repair previously, just take it slow and methodical. Stay organized when taking apart the dryer and keep all hardware with the corresponding components. Carefully inspect the dryer internals while open and address any issues beyond just the cord. Most importantly, always keep safety at front of mind whenever servicing electrical equipment.
By replacing a worn out cord yourself instead of either struggling with a duct taped mess or buying a costly new dryer, you save significant money and reduce waste. Given how frequently hair dryer cords fail, learning proper repair skills pays continuous dividends down the road. So be confident in your abilities, arm yourself with the knowledge above, and you’ll keep your hair styled for years to come!