Headphones Jack - Fix and Make Like New

We all love music so much and I'm sure we all hate when the audio starts interrupting and ... we loose one of the stereo channels or maybe both. Or those that have music controls can't change the track ... until bend the cable close to the jack.

It does not matter how much money you invest in headphones - their all weakest spot is the cable close to the jack....

Let's solve that.

This is not the next instructable that will show you how to solder a replacement audio jack to your busted headphones cable.

This is how I solved the problem with the audio jack.

Tools needed:

• Multimeter
• Soldering iron and soldering wire
• Craft knife
• Cable cutters
• Silicone rubber sealing adhesive - single component, neutral, general-purpose fast-curing

It is all about the silicone that you use. The one I have is liquid when applying and when it cures it becomes like soft rubber that is nicely flexible.

Steps to complete the instructable:

1. Cut off the cable close to the jack + remove another 3-4cm from the cable where it is most probably defective
2. Remove the cable insulation and measure where on the jack goes each wire - make a diagram
3. Remove all the rubber from the jack
4. Remove another 3-4cm from the cable's insulation
5. Inspect the wires and use the craft knife to scratch the insulation varnish off. If you do not do this, you will have problems with the soldering. There is another method that involves a lighter and you just touch the cable end with it to burn the varnish off.
6. Put some soldering wire on the cable ends and measure the resistance between the wires. You have to get a resistance of around 34 ohms for the left and the right channels. This will confirm your diagram from step 2.
7. Solder the wires to the jack. (Make sure you do not overheat the jack - it is very delicate.)
8. Test the headphones!
9. Gently apply the silicone using something thin - like a stick. Insure the silicone goes everywhere around the wires.
10. Put some stick and tape to hold the cable in the right direction. It will have to stay a day to cure completely.

Ready - we have done all the work, now let's enjoy the music for another lifetime. You will be changing the phone next time, not the headphones ;)