Melting or fraying MagSafe power adapter connections (MacBook, MacBook Pro)

We've received several reports from readers indicating an issue where MagSafe power adapters -- included with MacBooks and MacBook Pros -- fray or melt at the wire-to-head connection point shown to the right, or at the metallic connection point.

In some cases of the issue depicted to the right, failure is induced by excessive strain on the wire-to-head connection point. These failures are typified by exposed wiring and noticeable heat at the plastic split, The MagSafe connector is designed to disengage under too much pull, but significant stress can still be placed on the connection point at certain angles. However, it's unclear just how much strain can expose the underlying wires and melt the connection point. In-house, we've replaced the MagSafe adapter for a 15" MacBook Pro because of this issue. Though it's impossible to measure the total wire-strain placed on this particular unit, usage was not abnormal.

Apple takes a hard line on what it calls "strain relief damage" in Knowledge Base article #302461 which states:

"If the DC cable shows visible strain relief damage or if the cable is missing insulation or rubber in some areas, discard the adapter properly and do not use it again. Strain relief damage and missing cable insulation or rubber typically result from excessive force or improper use which are not covered by Apple's one year limited warranty. Replacement power power adapters may be purchased from the online Apple Store or from an Apple Authorized Reseller. If no damage is visible on the DC cable, contact Apple using the contact information listed in step 5."

In the case of melting and scorching at the metallic connection point (as shown in this picture), the cause is unclear. Potential culprits include dirty connection points and improperly gauged circuits, but we're still seeking information on more specific circumstances for the issue.

Feedback? Late-breakers@macfixit.com.

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