In June 2024, my brand‑new Hyundai Ioniq 5 (less than 2 months old, 1,700 miles) suffered a dangerous failure: the charging port electrically fused to the charging handle, trapping it in place. An emergency EV technician had to split open the charger and cut wires to remove it.
Here is the car "plugged" in with the charge handle not being able to release because of the wires which were fused internally. This ordeal lasted over 3 hours.
After the field technician from EV Connect came out, he had no choice but to split open the charger handle then had to cut the wires to remove this from the car. The white wire in photo is what fused inside the charge port as you can see on next photo.
Burnt in wire
The charging harness that is removed from the car showing a clear sign where electrical wire burned.
Burnt electrical connection
The other wires that were cut were able be pulled out of the charge port...except the white wire which is fused in as you can clearly see.
The dealership attempted to shift the blame onto me, by asserting that the issue was due to my mishandling of the charger stating, charging port was forced out without releasing the internal lock.
In reality, this tab was not locked in place at all as you can see in this video. The wires had fused, preventing the charger from releasing. EV Connect the charging station manufacturer had to come out and cut the handle off the car. After being cut off, it was very clear that one of the pins had fused in the car.
There is no sign of handle locked in car. The wires are fused to the handle which the charging company had to disassemble. They had to split the handle and cut the wires to remove it from the car.
This is a video I made after car was repaired to show what a locked handle in the charge port looks like.
When compared to the video I took on the day the wire fused to my car, it is VERY obvious the lock was not engaged the day of the event.
test showing pin activating which locks the handle in car
This is the charger handle outside the building at Rick Scott Hyundai. I took this video while waiting 4 hours for an "inspection" to take place. This video is to show the simplicity of a charge handle. Five pins that slide into the respective holes in the cars charge port and a simply designed locking lever above. A small pin within the car pops out to stop it from moving upwards. You can see this on the video above.
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