Update as of 9/5/2014:
I talked to Bosch on several occassions about this failure. The ticket got escalated after I provided an invoice from Nissan with the total cost of the repair. I had also provided them pictures and other information in the past week. I got a call last night from one of their managers. We had a nice discussion on my issue and the bigger issue at hand, the melted plug. It appears that the Rema plug, 6.6 kWh charging seem to be having an issue on some charging stations, regardless of brand. This just so happens to be the plug that was on my charger. I just got "lucky" and happened to be one of the rare cases where it gets a little too hot. Bosch is stepping up to the plate to make my situation right. Everything that I hoped would happen is now taking place. My car will be back to me tomorrow and I'll be back to enjoying my EV.
I have every bit of confidence that this failure will not happen again. I would recommend though that everybody with 6.6 kWh charging to check the brand of plug on their chargers. This whole experience was very stressful and took a lot of my time. I am happy to say that I give Bosch two thumbs up for how they brought resolution to the matter. I am very impressed with the customer focus of their management team.
I charge my Leaf and my Volt using a SPX Power Xpress. I purchased this unit in April. The first one received had issues (fault code issues) and was replaced with a new unit sometime in May. I've been charging with it ever since. I left a couple of weeks ago on a business trip. My wife plugged in the Leaf for about an hour. She then went out to the garage and put our 8-month old baby in the car. She noticed a strong electrical smell and immediately went to the front of the car. Smoke was coming out from the connection. She cut power to it and then unplugged it. The two top terminals on the plug and the receptacle were melted. The circuit breaker did not blow. No damage to the cord past the plug. All wiring back to the box is perfect.
Fast forward to last Monday when I return from my trip. I have enough range to drive it to the dealer (tow companies around here are terrible, didn't want it towed). They took pictures and sent them to Nissan Technical. They sat on it for 3 days before saying it was the SPX Power Xpress that caused the failure. No warranty and I'm on the hook for around $1400. I had called Bosch (formerly SPX) and sent them pictures as well. They are now waiting for an invoice from Nissan before deciding what course of action they will take. Meanwhile, the Leaf sits at the dealership waiting on parts.
Two HUGE issues for me here. I have a car that is less than 6 months old. Obviously it is under the manufacturers warranty. I have a charger. It is less than 6 months old and is under warranty. I am getting that feeling that nobody will pay and I will be on the hook for the bill. My other big issue is the safety factor. This could've resulted in property damage as the Leaf was in an attached garage or even worse, personal injury. Neither company seems to care about that, just how they can get out of paying the bill. I've been asked by Nissan and the dealer about it being an "aftermarket" charger. Wait, what? So every public charger I see I have to make sure it's a Nissan charger??? Not sure you will sell many EV's with that type of attitude. We all know that the "charger" is nothing more than a power source, just smart enough to send power when the car asked for it.
I am over a week into this and there is still no resolution. Nissan now says the part will "only" cost $500. I am out $1,000 on the charger as the plug is ruined. Who will pay? I am a huge EV supporter but this is making me rethink everything. I do know that not once have I ever feared GM would cover something on my Volt. I am scared every time I take the Leaf in that I will be handed a bill. Enough of my rant. Anybody that has any suggestions would be helpful. Here are a few pictures of that I took of the charger and the car.