Fixing a broken iBook G4 with Airport kernel panic issues

 by bicycletechnocrat
panic_3.jpg
Hello everyone!

Finally I accomplished something that is worth to make an Instructable about :-)

You are probably here because your good'ol iBook started acting weird after the update from Mac OS 10.4.8 to 10.4.9. In the manner that you allways get kernel panics (KPs) when you try to work with activated Airport-WIFI. For some people only when working on battery, for others all the Time.

In my case the notebook even sometimes refused to reboot after a KP and I had to leave it for about 15 minutes to cool down. But it definitively KP'd as soon as I switched Airport on.

I tried the widely distributed "paper-patch" where a folded piece of paper is put on top of the airport card, under its plastic holder to tighten its seating even more - with little effect. It only accomplished that I now could work for about half an hour before it KP'd again.

So hence the reason seemed to be a loose connection between the card and the mainboard (which the driver before the 10.4.9 handled flawless) and the connection between card and socket was tightened as it could be - more drastic measures had to be taken:

Once again I took the whole frickin' thing apart completely and this time removed also the mainboard to have total access to it from all sides. Since the socket is made of plastic, a hot-air reflow was out of question.
So - I manually resoldered all those tiny (ca. 0.3mm each) pins with the smallest tip in my soldering iron which i acuminated even more with sandpaper. And what can I say - after putting it back together, I started it up and loaded several ISO-images over the Airport-connection for hours and put it in standby once in a while.

It works perfectly now :-). No KP whatsoever since the repair. Not the tiniest hickup - the problem is completely gone!
 
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Step 1: Preparation

Since this Instructable is aimed more at experienced people who are aware of what they are doing I'll not be listing every single micro step. This is not a cooking recipe! Before you start make a mental inventory if you know the following things:

- How to work inside computers and what has to be taken in account when doing so.
- What electrostatic charges are - and how to avoid the damage they can do.
- How to solder and if you have a steady enough hand for this.
- How much heat can be inflicted on circuit boards and small electronic components.
- And last but not least if you are able to take this thing apart and put it back together.

When you can answer all of those with a yes, go ahead :-) - If not - you should better retreat until you can - before you have a completely broken unit afterwards.
trailofpen says: Apr 8, 2009. 11:34 PM
First try was a failure... You can see the frame in the pictures because I haven't removed it. I'm simply accessing the socket by lifting the frame, thus keeping everything attached, making it easier to test if it works or not.
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bicycletechnocrat (author) in reply to trailofpenApr 9, 2009. 12:17 AM
Sorry to hear that. But glad anyway that someone else tried it. Wasn't it pretty hard that way to solder the pins on the frame-side of the socket? Maybe you didn't reach each of them sufficiently. Are you good in soldering? I found it hard to solder on such a small scale since I wasn't able to optically tell if the tin flowed already correctly and if all the legs got proper contact or not.
bicycletechnocrat (author) in reply to bicycletechnocratApr 9, 2009. 12:23 AM
One more thing - be careful with the "lifting the frame"-part of your plan. Since its still attached to the board on some places it could bend the board and produce even more severe damage. For example breaking of a circuit on a lower layer inside the board.
jrhoda in reply to bicycletechnocratJun 14, 2012. 8:22 PM
Is there a way to do this without removing the heat-sink? I don't want to have to re-apply thermal paste...
mlamenasse says: Nov 20, 2011. 1:25 AM
Hey BT! thanks a lot for teh brilliant idea!.

As it's always easier to be improving rather tahn inventing, I thought that, maybe, if a resoldering solved the pb, it might just be a contact problem.

....and....

deoxit!

removed the keyboard, remove the airport card, spray the slot AND the card contacts with my favorite deoxit (you can find it in any guitar center, radioshack, etc...), wipe the excess liquid, and voila!

make sure to reinsert the card tightly.

it worked for me, at least
kjunior-1 says: Mar 14, 2011. 10:44 PM
I know it has been ages since anyone posted this but I've had iBooks do this and you're telling me all I had to do was use an older version of Tiger?
What about Leopard?
Finally, what about removing the airport card all together and using a USB wifi card?
These things are a pain to get apart without using a spatchula.

Thanks again.
Macworldwizardz says: Sep 18, 2010. 12:46 PM
Awesome Pic. of your iBook. My band director has an iBook G4 also.
trailofpen says: Apr 9, 2009. 1:01 AM
Worked the 2nd time around, but time will tell how long it will last. It wasn't that hard. The only part that was attached to the frame were the 2 hex nuts, so I had a lot of room to work with. I don't usually solder on such a micro scale, but I had nothing to lose with this. Thank you for your tutorial.
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Macworldwizardz in reply to trailofpenSep 18, 2010. 12:45 PM
Is that Mac OS X Tiger (10.4 to 10.4.11)
bicycletechnocrat (author) in reply to trailofpenApr 9, 2009. 1:20 AM
Great! Congrats! Tell me if it stops working again - mine still works on an on :-).
Macworldwizardz says: Sep 18, 2010. 12:43 PM
Apple has released a Mac OS X 10.4.11 Combo Update for PPC and Intel. In fact, they released it only a few years back...
doki_2 says: Aug 30, 2010. 3:07 PM
Hi All In my case and for the majority with this problem has the design mistake that Apple made that the connector’s contacts loose the strength from the worm that they were nearly permanently. The connector sit near to the processor cooler and to the HD. Not only that. The plastic that kept the connector was closed to the cooler channel of the processor. Even it is plastic and not pass the warm so much it is quite bad. If I was make such a final project in the school was not pass the exam. So it is not a soldier problem. Sure that any other soldering problem in the processor or in the BUS can make kernel panic. Anyway after 14 months of use I can not use the computer. Not it is 4 years and not bought any Apple products more. Best regards, Laszlo
doki_2 in reply to doki_2Aug 30, 2010. 3:18 PM
One more word for my earlier comment; I spoke about the airport card connector. In the earlier attached photos can see correctly what I mean. I was expect from Apple to admit this problem. Laszlo
woaini1116 says: Apr 19, 2009. 8:12 PM
got my dad to solder it today, and so far so good! i can actually turn it on without a KP and i'm using airport right now! thanks for the instructable. i'm so glad my dad used to work at IBM...LOL
bicycletechnocrat (author) in reply to woaini1116May 9, 2009. 4:48 AM
IBM is great! Love their Thinkpads (even if they sold them out).
woaini1116 in reply to bicycletechnocratJul 11, 2009. 1:09 PM
got a kernel panic this morning and now my airport isn't detecting any networks! =T
bicycletechnocrat (author) in reply to woaini1116Jul 11, 2009. 2:55 PM
Too bad :-/. But I guess its probably the same Issue. Maybe the resoldering was not 'thoroughly' enough. Ask your Dad if he's willing to do it once more - mine is still working perfectly.
woaini1116 in reply to bicycletechnocratJul 11, 2009. 3:08 PM
i let the computer rest and cool down, and now it detects networks again...screwy... =T
bicycletechnocrat (author) in reply to woaini1116Jul 11, 2009. 4:31 PM
Figures - materials grow and shrink with the rise and fall of temperatures. That hardens the suspicion that the solder connections got loose again.
woaini1116 in reply to bicycletechnocratJul 11, 2009. 7:20 PM
i opened back up my ibook, and applied more pressure to the airport...so far so good...
bicycletechnocrat (author) says: May 9, 2009. 4:46 AM
I'm happy to see that my instructable is usefull for those who tried it. Please don't forget to rate it :-).
liam01 says: Mar 20, 2009. 4:47 PM
i had one that has the same problem. i thought it was the airport so apple changed it for me n said it was all fixed. took it home and it wouldn't turn on, so apple then fixed it for free. turns out it needed a new motherboard. saved my self a good £400. i was pleased.
bicycletechnocrat (author) in reply to liam01Mar 21, 2009. 3:33 AM
Good for you - then you were lucky that your warranty was still valid. For most people this problem occurs after the warranty has run out. And the motherboard very likely had to be changed because of the poor solder connection on the Airport socket.

But even after hundreds of sightings of this problem Apple is not willing to take responsibility. Asus for example would admit a faulty manufacturing right away and replace everything - even after the warranty period ... but not Apple - they don't need to admit they fu**** up.

Thats why this instructable is here.
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