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How To Replace a Headphone Plug

Your headphones have stopped working, and after troubleshooting the problem, you realize the plug is broken. Replace the plug and get back to enjoying your music in private.

Instructions

  • Step 1: Solder the wires to the replacement plug. The ground copper wire is soldered to the longest pin, and the other two wires to the other two pins.
  • Step 2: Test the headphones by plugging them in. If they are working again, screw the outer case of the replacement headphone plug back on; if they aren't, well then maybe it's time to buy a new pair!
  • FACT: Jazz musician John C. Koss invented stereo headphones in 1958 so that listeners could enjoy hearing music from a portable phonograph without disturbing those around them.
  • TIP: Wash your hands before soldering the wires as the oil from your hands can affect how well the wires solder together.
  • Step 3: Tin the three wires of the cord by adding solder to their ends. Cover the ends of the wire completely, but don't add so much that it starts to drip.
  • Step 4: Cut the cord at the weak point with the wire cutters, and strip the insulation to expose the wires. There should be a right, left, and a copper ground wire.
  • TIP: For headphone cords made of two cables, there will be two copper ground wires. Twist the two ground cables together.
  • Step 5: Unscrew the casing from the replacement jack and slide it onto the cord.
  • Step 6: Test the headphone cable for the break by bending the wire around until the sound cuts off or crackles.

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