iPod Classic 6G — Replacement Headphone Jack (Thick — 160GB)

For safety, completely discharge the iPod before disassembly. This reduces dangerous thermal-event risk if the battery is accidentally damaged during repair. If the battery is swollen, take appropriate precautions. This iPod case is unusually hard to open without damaging major components. Its metal faceplate, metal backing, and thirteen metal clips make disassembly especially demanding. Caution: this opening method can significantly damage the iPod beyond its current condition. Keep a few extra plastic opening tools nearby, since they are easy to ruin while opening the case. Confirm that the hold switch is locked before you open the iPod.

Opening this iPod is challenging, so do not get discouraged if it takes a few tries. Watch the plastic opening tool tip angle as you insert it into the iPod; keep it as vertical as possible while still clearing the rear panel edge. Guide a plastic opening tool into the seam between the front and rear of the iPod.

Slide a second plastic opening tool into the seam between the iPod front and rear, keeping the two tools at least 1.5 inches apart.

Working at an angle, carefully slide a putty knife about 1/8 inch into the gap between the two opening tools. You will find thin metal rails running along the inside of the back panel, so work very carefully when inserting the putty knife. After the putty knife clears the rear panel lip, rotate it vertical and carefully but firmly work it straight down through the opening tool gap.

Press on the rear panel behind the putty knife with your fingers to reduce bending. Slowly flex the putty knife so most metal tabs along this side of the iPod release. The idea is to control how the rear panel bends instead of trying to prevent all bending. Any side bend should draw the rear panel lip away from the iPod, not push outward on the curved surface. This also releases as many side clips as possible.

Take the putty knife out, then place it closer to the iPod corner and use the same gentle wiggle method. If possible, do not bend the rear panel corner.

Between the lock slider and headphone jack, guide a plastic opening tool into the seam between the front and rear of the iPod. It may be easier to flex the putty knife downward carefully to create more room for the opening tool. Be careful not to bend the rear panel corner.

Near the display center, carefully slide a metal spudger into the gap made by the plastic opening tool. A visible bump can form here in the rear panel and is hard to repair. When levering the tab free, pivot the metal spudger on the rear panel edge instead of bending the rear panel outward. With the metal spudger, release the single clip at the iPod top edge.

Near the other top corner, insert an opening tool into the gap between the front and rear of the iPod

On the other side, insert an opening tool into the gap between the front and rear of the iPod. It may help to angle the opening tool stuck in the top corner to create enough of a gap.

Take out the plastic opening tool from the top corner and slide it into the seam between the front and rear of the device, leaving at least 1.5 inches of space between the 2 tools (as done on the other side).

Working at an angle, carefully slide a putty knife about 1/8 inch into the gap between the two opening tools. Again, you will find thin metal rails running along the inside of the back panel, so work very carefully when inserting the putty knife. After the putty knife passes the rear panel lip, turn it vertical and carefully but firmly work it straight down through the gap between the plastic opening tools. Press on the rear panel behind the putty knife with your fingers to reduce bending. Flex the putty knife just enough to make sure most metal tabs along this side of the iPod release.

The metal clips near the corners grip the front panel tightly. Release these clips before opening the iPod. Carefully slide a metal spudger into the area beside the stubborn metal clip.

Gently work the metal spudger downward until it is fully seated in the rear panel.

Gently start releasing the clip from the front panel. A visible bump can form here in the rear panel and is hard to repair. When levering the tab free, pivot the metal spudger on the rear panel edge instead of bending the rear panel outward.

Use the metal spudger to apply upward pressure under the front panel until the metal clip releases.

You will find two ribbon cables connecting the rear panel to the remaining iPod assembly. In the following step, take care not to damage these ribbon cables. In this step, grasp the front-panel assembly with one hand and the back panel with the other. Pause for a moment before continuing. Very gently release the remaining rear-panel clips by pulling the tops of the front and rear panels apart, using the iPod bottom as a hinge. Take great care not to damage the ribbon cables joining the two halves.

The battery flex cable lock tab is very delicate. Pulling too far, or pulling on the connector's white portion, can tear it from the main board. If that happens, battery connector repair becomes very difficult. With angled tweezers or an opening tool, raise the brown lock latch straight up by 1 mm. Confirm you draw from both sides of the latch. Take care not to pull on the white portions extending to the connector's outer edges. Move the brown lock tab straight upward. The connector is fragile and can break if it shifts to the side. Grasp the flex cable with your fingers or tweezers and draw it straight up to detach it. If using tweezers, avoid grasping the cable too close to the socket or the cable contacts may short.

Set the rear panel beside the iPod, taking care not to strain the orange headphone jack cable.

Raise the hard drive with one hand to expose the headphone jack ribbon underneath. With a spudger, flip up the plastic tab securing the headphone jack ribbon in place. The tab can rotate up 90 degrees, releasing the ribbon cable. Move the orange headphone jack ribbon out of its connector. The rear panel is now released from the iPod.

After opening, check the rear-panel clips. If any clip bent upward, press it back down gently so the rear case can close cleanly.

Use the broad, flat face of the metal spudger to press the clip downward. Work carefully so the thin metal rail does not tear away from the rear panel. Flat pin-nosed pliers can reduce slipping and headphone jack damage risk. While shaping these clips, take care not to damage any headphone jack parts.

Set the rear panel on its side on a clean, hard surface. Carefully but firmly press it downward, rolling the full lip edge back into place. You may need to repeat this several times to straighten the sides well. Slightly overcorrecting the case edges inward is better than leaving them too far out, because reseating the front panel will bend the rear panel back into alignment. Once the rear panel is restored to good condition, continue with the iPod repair.

The battery sticks to the rear panel adhesive. As you remove it, take care not to tear the orange ribbons for the headphone jack or hold button. With a spudger, raise the battery and the attached orange cable out of the device. If you have a 160GB iPod, the battery will be thicker than thinner battery variants. If the battery is hard to remove, warm the OUTSIDE of the rear panel with a hair dryer on its low setting for 20–30 seconds — never a heat gun, and never heat aimed at the cell. If the pack is swollen, discoloured, or warm to the touch, stop: do not pry it and do not heat it. A punctured or overheated cell can vent or ignite.

Hold the orange ribbon cables in place with one hand, then peel up the black tape securing those cables to the rear panel with your other hand.

Take out the two black Phillips screws securing the headphone jack to the back panel. These screws are small; make sure a size 00 screwdriver is on hand.

Take out these two screws: Fastener detail: one black Phillips screw holding the hold switch near the corner of the device. Fastener detail: one silver Phillips screw securing the other edge of the hold switch.

Raise the hold switch free from its housing on the rear panel. Do not remove the hold switch completely yet because it shares the headphone jack cable.

Move the headphone jack out of its housing on the rear panel. Raise the headphone jack and hold switch assembly out of the iPod.

If you're just trying to take out the rear panel, you can skip Steps 30 and 31. If the replacement headphone jack includes the white plastic hold switch, reinstall the replacement headphone jack. When replacing the hold switch assembly, align the locating pin near the silver screw hole first; the rest then settles into place. After the screws are in, remember to peel the backing tape from the contact pad along the jack. If the replacement part lacks the plastic hold switch, use the next steps to transfer the switch to the new headphone jack. Take out the single Phillips screw nearest to the hold switch. Raise the plastic part of the Hold switch away from the orange ribbon cable. During switch reassembly, confirm that the black notch lines up with the gray slider.

With the small plastic opening tool, carefully peel up the orange ribbon cable and attached black Hold switch from the metal backing. When attaching the replacement Hold switch, align the two small rear posts on the switch with the two holes in the metal backing.