Bose Sound Dock Repair and Update With Bluetooth

We have an old Bose Sound Dock which was used with an iPod. Both the sound dock and the ipod quit working after about 12 years of use. In this instructable we will look at how to open up and get into the sound dock and the options for repairing it and modernizing it so that it is Bluetooth capable.

What you will need for supplies:

- Amplifier and bluetooth module - anywhere from 3 to 100 Watts should work. There are lots of options available on Amazon. I first used a Bluetooth Amplifier Board DC12-24V 100W+100W 4.1 TDA7498 Digital Power Amplifier Module: https://www.amazon.ca/dp/B07LH5FYNR/ref=cfb_ai_pro... However I would not actually recommend this as it has a really annoying loud pop everytime the bluetooth connects and disconnects or when you stop and start playing music. You live and learn, I may replace this with something else later, but it does play music nicely once its going. What ever you get, check the dimensions and make sure it is small enough to fit inside the dock.

- Recommended bluetooth board DROK SKU:200336 https://www.droking.com/Bluetooth-Digital-Amplifie...
use it without the shell

- Scrap of vector board, prototype board.

- #24 Gauge wire

- Glue or hot glue

- Solder

Tools:

Soldering iron

Solder sucker or braid

Hot glue gun

Wire cutters

Wire strippers

Screwdrivers

Pliers

Remove the 4 phillips head screws holding the base in place. Keep the base and screws for later.

Once you remove the base plate you can just lift out the entire tray assembly. There is a ribbon cable connecting the processor board and dock. This is just a friction fit, pull on it and it will come out. Unless you plan to replace the boards with original Bose boards you can discard this cable.

Remove the front grill by very gently prying it up. it is just a friction fit and will come off easily. Keep the grill for use later.

Undo the 4 screws holding in the power amp heat sink, located in the centre of the sound dock. The power amplifier is attached to rear side of it. Just gently lift it out. Keep the heatsink and 4 screws for use later.

There are 6 (star shaped head) screws holding the power amplifier and heatsink together. Remove these screws and save the heatsink and screws for later use. Separate the heatsink and amplifier.

Disconnect any ribbon cables and discard. Unplug the two speaker cables (Red and Black wires with a white jack on the end) by pressing the tab on the jack and pulling. Discard the power amplifier board.

Cut the white connectors off the speaker wires, strip the end of the wires back about 1/2 a centimeter and tin with solder. (Unless you happen to have a new power amp that uses the exact same connector type - not very likely but possible)

Using a soldering iron and solder sucker or braid remove the power connector from the sound processor board.

Cut a piece of scrap vector board to fit in the tray and accommodate the power receptacle you just removed from the Bose audio processor board.

Solder the receptacle to the vector board so that it is centred and in the correct position horizontally to protrude from the rear of the case.

Solder power wires, red for +18V and black for ground to the receptacle. Use pieces long enough to run to the amplifier board when it is in place. Use a voltmeter to make sure that you are connected to +18V and Ground.

Dry fit it in the tray and place in the sound dock to check that the connector and the vector board are in the correct positions.

Once you confirm correct wiring and fit, use hot glue to fix the vector board in place in the tray.

Place the new amplifier with bluetooth board on top of the bose sound dock and connect the speaker wires and power wires. Be sure to respect the correct polarities.

Power it up and check that everything is working. Connect your music source via bluetooth. Check both speakers for sound.

Put the new board inside the space behind the original heatsink and hot glue in a couple of spots to hold it in place.

Make sure the power wires are placed in the spot where the ribbon cable used to run so that there is enough room for them when you attach the front grill.

Put the original heatsink back in place and fasten in place with the 4 original screws you took out.

Put the grill back in place and check that the power wires are running through the spot where the ribbon cable used to run and not crimped by the grill.

Put the tray in place and make sure that the rear power connector is inserted in the hole at the back of the sound dock.

Screw the base plate back on with the 4 original screws you took out.

Assembly is now complete. Power up the dock and connect to bluetooth.

Enjoy the music!