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A few checks with the multimeter against the pinout indicated everything was connected correctly, and plugging the charger back into the Macbook indicated the repair was successful. After cleaning up the solder tabs of the connector, I freshly stripped the charger wiring and soldered everything back into place. This explained the symptoms we were seeing, so I was confident that I’d found the root cause. The issue was that after many years of use, the continual flexing of the cable had caused the shielding strands to break over time, eventually making poor or no contact. The center conductor is soldered to one tab which connects to the V+ pins of the Magsafe connector, and the shield connected to the other tab, leading to GND. The cable of the Macbook charger consisted of a centre conductor sheathed in Teflon, which was then surrounded by two layers of shield wound in opposite directions. After much consternation, I had the connector peeled back and was able to identify the problem. A Dremel would have been the perfect tool for the job, actually, but I persevered regardless. I began to strip away the metal shell around the back of the connector with my sidecutters, and eventually an angle grinder. Replacement parts simply aren’t available - a common problem with proprietary connectors. It’s at this point with any other charger that you get out your trusty sidecutters, lop the end off, and tap away at Digikey to get a replacement part on the way.
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The soft metal is fairly easy to cut with hand tools. Sidecutters weren’t the best tool for the job, but they’re what I had lying around. This led me to suspect an intermittent connection was the culprit, and it was quite a poor one at that the high resistance leading to the heat issue. The other, was that even when it would charge, the connector would become very hot. The first was that the charger would only function if the cable was held just so, in exactly the right orientation. However, it’s not the easiest to fix. When the charger began failing, I noticed two symptoms. This connector has many benefits, such as quick release in the event someone trips over the cable, and the fact that it can be plugged in without regard to orientation.
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Unlike most PC manufacturers, who rely on the humble barrel jack and its readily available variants, Apple liked to use the Magsafe connector on its Macbook line. Such was the case when I found myself face to face with a failed Macbook charger, and figured it’d be a simple fix. It’s usually the connector that goes first. Combine this with fairly lightweight design and it’s not uncommon for a laptop charger to fail after a few years. They’re repeatedly plugged and unplugged, coiled up, stuffed into bags, thrown around, and just generally treated fairly poorly.
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