How to Fix a Broken IPod Charging Cord





Introduction: How to Fix a Broken IPod Charging Cord

My iPod is actually almost dead while I am making this instructable, and actually does die before I finish it.

Step 1: The Problem

Here's the problem! After about two years of constant use, way into the wee hours of the night, my iPod cord broke right at the base of the plug. I should throw in the towel, accept that I had a good run with this cord, and go buy a new one right? WRONG!

Step 2: What You Need

-Broken iPod cord
-A flat working surface(for me it's my bathroom floor)
-A knife, not the sharpest, as you will be doing some delicate cutting
-Scissor, or for me the cutter in my multi-tool
-One heat shrink tube, I had some, but you can get them at radio shack
-Electrical tape
-White tape for structural purposes

Step 3: Open It Up!

With the knife, very carefully separate the outer casing for the plug. Mine came apart rather easily, but be careful as to not cut anything inside, or to cut you!

Step 4: Here's What You Have

This is what you should see, simply remove to plastic case.

Step 5: Time to Cut!

Cut the wire where it broke at. Not at the plug! You could probably re-solder the connection from here, but I don't have to tools for that.
Remove the plug head from the thick rubber piece and you should have about half an inch of wire to work with. This is perfect!
Remove the rubber outside from the plug wire, and you should see the wires wrapped in a foil.

Step 6: Remove the Foil

Remove the foil to expose enough wire to work with. Separate the wires on the plug wire and plug head

Step 7: Very Carefully Now!

Here is the most delicate part. If your knife is too sharp you run the risk of cutting through the wires. Mine was a little dull, but that was perfect. Just start cutting the red and black rubber to expose the wire. Do this slowly!!! You should feel when you meet the wire with your blade. Stop cutting once you feel it! Work your way around the wire and carefully remove the rubber housings. Do this for both the plug wire and plug head.

Step 8: Here Is Where I Died

My iPod actually died at this point, but no pictures are really needed. At this point slide the heat shrink tubing onto the plug wire down past the exposed wires. You will use this soon. Simply twist together the corresponding wires to make the connection. At this point I warped a small piece of electrical tape around each individual pairing. Not a lot, just once over to keep the wires from touching. The I wrapped one piece around the entire grouping. At this point just slide the heat shrink tubing up and over the area you are working. I used a butane lighter to shrink the tubing, but you can use a regular one as long as you are careful. After it has cooled down, replace the plastic plug casing you removed in the first step

Step 9: Tada!

Now the plastic case may not snap back together. If you look it goes a certain way, and once you find that you can do once of two things. Either run a small bead of super glue along the edge before you press it together, or do like I did and wrap some tape around it. Plug it in and test it out, it should be running like a champ! Enjoy !



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    25 Discussions

    I use this one to protect my cord, really works, cute & functional

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    1 reply

    A couple friends and I are working on trying to strengthen charging cords. If yall could take this survey really quick it would help a lot!

    My ipad cord had two weird lumps by the place just before u plug it in plz help


    the iPod charger was plugged into fast and now the iPod won't charge

    What had happened was one of the wires had snapped. Sugru can't fix that

    1 reply

    Omg this instructable was posted 3 years ago. Obviously things have changed since then

    You can literally download 4 apps and get a free charger anytime you want from lol

    Any chance this would work with a MacBook charger??

    1 reply

    Mine was broke where the company that manufactured it soldered it onto the micro chip. I did not have solder so I used hot glue to stick it onto the solder. You have to be very extremely precise for this. Hot glue is not a conductor and if it's too hot the entire thing is ruined. You have to get it where it just starts to melt. So that means sitting there pressing the trigger till something comes out. I also had take my knife and expose the wire as well but only a little bit. Also cut the entire white caseing off of the charger because it wasn't one that clicked together.. So when I had to put it back together I covered the head part with hot glue or you can use electrical tape. I didn;t have electrical tape. This should only be a quick fix if you are waiting till a new charger comes in the mail. Not a good idea for long term fix. Be sure to keep this away from fabrics and such just in case... I do not want to be responsible if your house catches on fire. I've been in robotics for 3 years so I knew what I was doing. I do not highly recommenced this if you have no exprience with wires or mechanics...

    I find that the spring and heat shrink approach does a really good job protecting the cable where it meets the connector. They are for sale on ebay here: if anyone wants to go this route.

    you can just order a new cable for free off of just saying

    Didnt work for me, tried on serveral of my broken chargers

    I actually had to take them completely appart and found it was where the wires were connected

    Hunter M4 is correct it died during the repair, once fixed it worked fine. It still worked up until I upgraded to the iPod 5. I posted this two years ago, so cords weren't 50cent apiece or at least good ones weren't . Glad this helped some people , wish I knew why you felt the need to continue to question this instructable

    my ipod was sitting around for 2 years bec i was so pissed off that the damn charger is so freakin expensive. THANK YOU SO MUCH FOR THIS! i'm charging it right now and i feel so happy yey! :)

    1 reply