Fixing a broken wire in a vape pen battery can be challenging and potentially dangerous, as it involves working with electrical components and lithium-ion batteries. It’s essential to prioritize safety and consider the following steps:

Caution: Always proceed with caution when attempting to repair or modify vape devices. Mishandling lithium-ion batteries can lead to safety hazards, including fire and explosion risks. If you’re not confident in your ability to perform these steps safely, it’s best to seek professional assistance or replace the battery.

Here are the steps to attempt a repair:

Materials You’ll Need:

  1. A replacement wire (ensure it’s suitable for your vape’s voltage and current requirements).
  2. A soldering iron and solder (for soldering).
  3. Heat shrink tubing or electrical tape.
  4. Safety goggles and gloves.
  5. A well-ventilated workspace.

Steps to Fix a Broken Vape Pen Battery Wire:

Safety First:

  • Wear safety goggles and gloves to protect yourself during the repair process.

Disconnect the Battery:

  • Ensure the battery is completely disconnected from the charger and any attached components, such as the atomizer or tank.

Inspect the Damage:

  • Carefully examine the broken wire and determine the extent of the damage. If the wire is only partially severed, you may be able to repair it. If it’s severely damaged or close to the battery terminal, it may be safer to replace the battery.
How to Fix a Broken Vape Pen Battery Wire

Cut the Wire:

  • Carefully cut the broken section of the wire away using wire cutters or small scissors.

Strip the Wire Ends:

  • Strip a small amount of insulation from both ends of the wire, exposing the bare metal.

Prepare the Replacement Wire:

  • Cut a suitable length of replacement wire and strip both ends.

Solder the Connections:

  • Use a soldering iron to solder the replacement wire to the existing wire ends. Ensure you have a secure and clean solder joint.

Insulate the Connection:

  • Slide heat shrink tubing or wrap electrical tape around the soldered joint to insulate it and prevent short circuits.

Test the Connection:

  • Reconnect the battery and test the vape pen to ensure it’s functioning correctly. Pay attention to any signs of overheating or unusual behavior.

Reassemble the Device:

  • If the repair is successful, reassemble your vape pen, including the tank or atomizer.

Monitor for Safety:

  • Keep a close eye on your repaired vape pen for signs of any issues, such as overheating or abnormal behavior. If you notice any problems, discontinue use immediately.


Remember, attempting to repair a vape pen battery wire carries risks, and it may void any existing warranties. If you have any doubts about your ability to perform the repair safely or if the damage is severe, it’s safer to consult a professional vape technician or consider replacing the battery or the entire device. Safety should always be the top priority when dealing with vape batteries.