You can't, it's all molded together. Once a plug is broken you have to buy a whole new cord. One of the reasons these things suck so much. Good money maker for Festool. [thumbs up]
In the past they offered a new plug you could fit yourself, but they stopped doing that. But the new plug was only 25% cheaper than an entire new cord anyway.
Since the plug itself still works fine, I was hoping it could be removed, slide the strain relief down over the insulation and reconnect. This cord is probably ten years old if that makes a difference. Since green on festool is supposed to indicate that it has a purpose, thought I might get lucky.
I suggest to split a larger size(bigger than the cable) shrink tube and heat it over the connector. It will make it stiffer but at least will protect it a bit more.
In what way does your cord look different? All Plug-It cords, Protool or Festool, are made in the same way, all molded together and not user serviceable.