Headphones consist of a wire, a plug and two speakers. Additionally, the headset is equipped with a microphone and volume control. Any of these elements will eventually fail. Before making repairs, you need to find out how to disassemble the headphones, so as not to break them permanently.
Content:
Disassembly and repair of plug
Find the fault of the plug by kinking the incoming wire with the fingers of your hands. Headphones are connected to a cell phone or computer, play a music file, and then proceed with the diagnosis.
Usually the copper strands are broken at the inlet of the rubber or plastic cover of the plug and inside the plug. If there is a sound in the speakers at times while the cable is kinked, then the plug must be disassembled and repaired.
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The procedure for repairing the plug consists of the following steps:
The plug is bitten off with pliers from the headphone cable.
The purpose of the repair is to remove the metal part from the casing. The element is firmly soldered in. It is unwise to try to keep the old casing. It is easier to cut it lengthwise with a sharp knife.
The metal part of the plug is carefully removed from the casing so that the contacts do not break off. The soldered wires should also be saved. The color of the insulation makes it clearer where to solder the wires of the headphone cable.
In the case of broken cores from the contacts on the solder itself, the standard scheme shown in the photo is used for connection. The color of the insulation in the headset cable differs from manufacturer to manufacturer. Most often the common core is in black or yellow insulation. To be sure, it is better to test with a tester from the speakers to the place where the cable is cut.
Headphones can be equipped with a microphone. In these models, under the braided cable instead of three hidden four wires. Connection is made according to a different circuit, shown in the photo.
The cable cut from the plug is stripped. First remove the main braid and free the ends of the cores. The edges of the thin wires are stripped with a sharp knife. It is enough to remove 5 mm of the insulation to solder the copper wire to the connector pin.
The wires are twisted from thin strands, and they are all coated with a protective varnish. This coating prevents soldering. The lacquer is removed by scraping with a knife or by burning with a lighter. The ends of the clean copper strands must be tinned. The common wire will connect on the same pin, so it is soldered together at once.
A new cover for the plug is made from the bottom cap of a ballpoint pen. The wire is inserted through the hole for the writing rod. The fitted cap is pushed along the cable further away from the soldering point.
Following the cap, a piece of heat shrink tubing is placed over the wire. The shrink tube will protect the wire from breaking near the new plug cover.
The wire strands are soldered to the pins of the plug. It is important not to forget to match the wires with the color of the insulation. Functionality is checked by testing with a tester. It is easier to connect the plug to a cell phone or computer.
If both headphones work properly, a heat shrink tube is put on the contacts of the plug. It is heated with a lighter. The tube will fit tightly around the pins of the plug. To be sure, you can crimp with your fingers while the plastic is hot.
Finally, the inside of the cap is coated with epoxy. A small amount of glue is applied to the heat shrink tubing. The cap is pushed over the cable until the back of the plug is fully seated up to the stop. After 24 hours, the resin will harden and the headphones can be used.
Disassembling vacuum headphones
The wire can break not only on the plug, but also near the speaker. To vacuum headphones to get to this part perform the following steps:
On the body of the headphone find a seam. On it try to make an incision with a sharp knife. The housing is lightly pressed with the pliers so that the seam separates.
When the case falls apart in two pieces, the back of the speaker with the contacts will be visible. The damaged wires are soldered with the soldering iron, but first mark the insulation color with a marker so as not to mix up the wires.
From the common cable of the headset cut off the damaged piece. Strip the cores from the damaged wire, and then solder them to the contacts of the speaker, observing the marks of the insulation color.
The operation of the vacuum headset is checked by plugging it into the phone or computer jack. If the sound quality is not intermittent from the speakers, the halves of the headphone body are glued together.
Disassembly and repair of large headphones
The speakers in large headphones are hidden inside the body, disassembly is complicated by hidden screws and latches. If all the fasteners are not revealed, the plastic elements of the headset will simply break from the applied efforts of the hands. Methods of disassembly of headphones from different manufacturers differ. For example, let's look at a few popular models:
To disassemble the headset Sennheiser HD203 begin with the removal of the ear cushions. The soft pads are held in place by latches that can easily be detached with a plastic card.
Under the soft pads there are four screws. They are unscrewed with a screwdriver.
The halves of the case are not glued together. After unscrewing the screws, the elements can be easily separated into two parts. On the front panel the speakers are attached, to the contacts of which a new wire must be soldered.
The manufacturer of the Steelseries Siberia headset glues the soft pads in place. The cushions are separated from the case with a screwdriver or a knife. The mounting of the case halves in different models is used with screws or latches. In the second case the disassembly is not done without breaking off the locks. The hull with broken latches is assembled with glue. A firmly glued earpiece cannot be disassembled in the future.
Things are easier with the soft pads in the Razer Kraken headphones. The ear cushions are simply put on without glue or snaps. After removing the pads a paper sticker comes into view. Under it there are four screws.
With Philips and Audio-Technica headphones the ear cushions are similarly not fixed in any way. The pads are just put on the cup's rim.
Disassembling the microphone housing with volume control
Headphones for the computer are made with a volume control and microphone. The cell phone headset is equipped with a talk on and talk off button. All these elements are hidden in a small plastic case attached to the cord. To get to these elements you will have to perform the same actions that are used to disassemble the vacuum headphones. The case is glued and can be divided into two halves only by cutting with a knife.
Failure of the volume control is determined by the crackling in the speakers and bad sound. The problem lies in the variable resistor. The part consists of a slider that moves over a resistor layer. You can extend the life of the resistor with graphite grease. Use a cotton swab to grease the resistive layer.
The problem with the microphone is detected by the deterioration of hearing that is experienced by the caller with whom the conversation is taking place. The cause is often clogging. The microphone is wiped with absorbent cotton or gauze soaked in alcohol. After repairing the resistor and microphone, the two halves of the housing are glued together.
Disassembling headphones of any brand is not difficult. The main thing is to be careful. Broken plastic parts cannot be repaired.
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