I cut around the top end of the charger with an abrasive cutting wheel on a Dremel tool. See the dotted yellow line I added to the photo.
Knife for stripping wire
Hot glue gun
Step 2: What I found inside
The pliers grip a small steel spring that should be soldered to the circuit board and touches spring clip that grips the sides of the cigarette lighter socket. The small steel spring broke away from the circuit board as soon as I pressed on it to bend it a little. If the small steel spring overheated a little, it would lose its temper and would not make good contact with the spring clip. Somehow, the contact between the small steel spring and the spring clip was not as good as it should be, and this is why my charger worked only sometimes.
Step 3: Does it still work?
I connected the alligator clips from a 12 volt charger to see if the LED still lights. The car charger still works.
Step 4: The plan
I decided to solder a flexible jumper wire between the circuit board and the spring clip. All that needs to be done is to stuff the assembly back into its case.
Step 5: Change of plans
The spring clip would not slip into the charger's case because the circuit board kept it from compressing enough. I had to insert the spring clip into the case and then insert the circuit board. But, things began to go wrong. First, the jumper wire I used took too much space and I had trouble stuffing the circuit board into the case. Perhaps things would have been different if I had used magnet wire. Then the jumper wire broke off at the circuit board. It should have been simple to solder the jumper wire back in place.
Bio:I miss the days when magazines like Popular Mechanics had all sorts of DIY projects for making and repairing just about everything. I am enjoying posting things I have learned and done since I got my...read more »