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Replacing the jack on a pair of headphones

Replacing the jack on a pair of headphones
Got a pair of perfectly good headphones you need to toss cause the jack is broken? This instructable will show you how to replace the jack
 
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Step 1Parts and tools

Parts and tools
Along with the fairly standard soldering iron, a new jack, and such, there's a few other things you'll need. You'll need a box cutter or X-Acto knife to score the outer cable before using a cable stripper to remove the outer covering. You'll also need a microtorch, and a hot glue gun. some people also like to have a little paper or electrical tape, but in my case, i've chosen not to use it. You'd also note two different styles of 3.5mm TRS Jacks- You only need one - the plastic sort is cheaper and looks more 'original', but i prefer the metal one- i've had the plastic ones fall apart post soldering at least once, despite being internally very similar.

Helping hands also are useful - jacks are tiny and need clamping.
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54 comments
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Dec 17, 2011. 11:30 AMcwhyhache says:
hi, i have a pair of spoilt earphones and i really liked to have them fix. however, i do not have those tools (like soldering iron, glue gun..) i see that you're from singapore too. i would really appreciate it if i could send (through mail or somehow) it to you for repair. (if you don't mind) & i don't mind paying a bit for the service..

please mail me a reply. thanks! :D
yuhuii__@hotmail.com
May 21, 2011. 3:51 PMA.I says:
Thanks for posting this! Extremely helpful! Didn't even need the hot glue, worked like a charm. :)
Mar 22, 2011. 11:49 AMisottomayor says:
What the Buthane Toch is?
Mar 3, 2011. 8:01 AMIsurvival says:
I have bought a very good headphone,but the cable broke at the jack, and i would like to ask, if i change the jack, will it affect the quality of the sound? I would like to know, before i change it...thanks for your help in advance-very good instructables by the way :)
Mar 4, 2011. 11:33 AMIsurvival says:
Thanks for the info, and the help-this instructible is really helpful for the ones like me, who don't really know how to deal with electricals, and for sure, it will sound better with a working jack than without :D

By the way, my granfather helped me a bit with the soldering, and it works like the new :) I'm very happy adout it, so thanks again
Jul 29, 2010. 12:49 PMmoccor says:
is it possible to solder both a 3.5mm and 2.5mm headphone jack onto the same set of earphones? to switch between both sizes whenever needed. or would that damage a device and require some sort of switch to block off the other jack?
Aug 6, 2010. 9:46 AMmoccor says:
Do you think it would blow out the speakers or maybe ruin a headphone jack on a phone/computer ect? I kinda want to try it
Jul 7, 2010. 2:39 PMpeyo says:
um where did u get that jack i tried using one i had in my house i guess thats not the one i needed cuz i took it apart and it was all plastic and it didnt those two little things to attach the green and red wires im mad as hell this is confusing
Jun 30, 2010. 5:57 AMdoctorpsyco says:
where did you find the replacement jack? how much did it cost?
Jun 12, 2010. 8:14 AMmoccor says:
can this be used to cut the 3.5mm jack off earphones and switch it with a 2.5mm jack?
Jun 13, 2010. 6:01 PMmoccor says:
well im sure sound will come out of atleast one of the earphones rite? it would be awesome if both left and right worked, but aslong as it will work partially and have sound com out of either side, im fine with that. do u think theres a guarantee atleast one side will work when converting to a 2.5mm from 3.5mm? i kno ur not held responsible for anything
Jun 14, 2010. 10:12 AMmoccor says:
ok i tried it. the first time i tried using a used 2.5mm jack and cutting away at all the plastic and crap to get to it. but that was messy and hard to work with so i failed. but then i just cuz the jack off another 2.5mm earphones, and soldered it to the 3.5mm wires, and it worked perfectly
Apr 7, 2010. 1:33 PMxbdude says:
Hi i was wondering where you got the metal TRS jack i could only find plastic black ones (Canada, Toronto)
Mar 29, 2010. 3:33 AMLeviMan_2001 says:
Awesome instructable! I never thought about cleaning the wires with fires! I'm listening to my previously broken headphones right now haha
Feb 19, 2010. 5:13 PMfiola says:
I've done this several times to save the life of some crappy headphones that flatten the high tones but reaaally boost the low ones. And even though it works it always end up with a bad contact for one of the headphones.

Any suggestions???
Feb 22, 2010. 10:46 PMinlikeflint says:
I dorked my original jack on my Sennheisers ($100.00+ headphones)... I have tossed many headphones, and earbuds, but I have to fix my Sennheisers because they have been the best cans I have ever owned. I had not thought of hitting up Radio Shack for a metal jack, but now I am and this tutorial has me stoked. Thanks for posting this...
Feb 22, 2010. 10:57 PMinlikeflint says:
.... I have the PX 100's that fold up like sunglasses. I thought about getting the model you have but I had to be able to hear things in my surroundings and not totally tune out. These headphones are the best, and when my jack broke I was so bummed. (I'll have mine fixed by tomorrow... Thanks again!)
Dec 12, 2009. 8:47 PMFreak_09 says:
Em, I have a problem....my earphones cables are too thin, they tend two broke if I twist them the wrong way. But I tried and they do work when connecting them to the jack, so, I was thinking about using an ipod earphones cord to: 1) make my other earphones cord longer and 2) make the jack connection not so fragile. What do you think? can it be done?
Dec 12, 2009. 11:14 PMFreak_09 says:
I agree with you it may not be worth fixing it, but, to tell you the truth, I'm kind of a maniac and got these black ladybug shaped earphones....so I don't really want to dispose of them so easily. I've read other instructables where you unsolder the wire from the speakers and solder a new one, but for this you need to open up the speaker case, which seems rather imposible with mine. Argh....should give it a try?

Jul 7, 2009. 12:59 PMFocker says:
I have at least 4 pair of headsets that have bad jacks, and every time I tried fixing them they would not work, then I saw step 4 and it all makes sense now. I never scraped or burned off the enamel coating which is probably why I couldn't get signal. Great ible!
Jul 30, 2009. 11:17 AMsafdar says:
olden day headphones have copper wire without the enamel but the wires are very fat and stiff which can get annoying
Jul 7, 2009. 1:29 PMyoricktf says:
hey is there anything else you can use aside from microtorch, lets say, a gas stove???? or maybe even a plain lighter??
Jul 30, 2009. 11:14 AMsafdar says:
you can use a lighter and then use sand paper to clean the wire up a bit
Jul 7, 2009. 4:47 PMosgeld says:
plain lighters are not all that clean burning, leaving suit all over the wires your trying to clean (altho you CAN do it) anything with a blue flame should work fine
Jul 19, 2009. 8:47 AMEleriK says:
A torch lighter counts as a microtorch, right? (the kind that makes the small jet of green/blue flame)
Jul 18, 2009. 5:52 AMcapricorn says:
Praises to you my friend, I was so tired of wasting material everytime a cable broke. Really something good to know
1-40 of 54next »

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