Question about Bose Aviation Headset X Headset

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I need the wiring diagram (pin-out) for the Bose headset X to repair the wiring of the jack of the headset (not the aircraft jack)

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SOURCE: I need for Bose X headset connector wiring diagram

It's in the manual I think

Posted on Mar 30, 2011


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Headphone speakers stop functioning properly when the wireconnections to the speaker are broken. This problem often develops when theheadphone cord gets jerked while being worn. The solder connection might alsodetach over time if it was not properly manufactured. The wire can bereconnected to the speaker with a soldering iron to repair the headphone. Beaware, though, that headphones are not designed to be user maintained in thisfashion. In some cases, it is difficult to get to the speaker due to the casingdesign.
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Screwdriver or butter knife (depending on headphone design),Soldering iron, Electrical solder
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4 Touch the tip of thesoldering iron to the electrical solder. A small drop should melt onto the tipof the iron.
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6 Touch the end of the wire tothe solder on the metal tab attached to the speaker.
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I have lost sound in the left earcup of my Bose QC3 headphones, although sound comes from the right earcup. How should I proceed to fix it?

The solution to this problem is not for the faint hearted. You will break your headset, you will void your warranty, and you quite likely will end up with a non-working headset. You will also have to solder very small electrical components.

I also had the left channel audio not working, so the first thing to do was to take apart the headset.

Step 1. Remove the battery. Remove the two tiny screws from under the u-shaped plastic piece that holds the earpiece to the headset. You will have to pop out the end furthest from the audio jack. A #0 phillips is needed. Put the tiny screws in a safe place.

Step 2, Break the silver cover free from the black plastic earpiece by sliding a flat blade screw driver down between the joint towards the bottom of the earpiece. Be very careful not to insert the screwdriver blade too far into the earpiece because the circuit board is just inside. For some reason Bose decided to glue the two attachments for the bottom of the silver cover to the earpiece.

Step 3. Unscrew the 3 screws holding down the circuit board and put them in a safe place. Gently pull up the circuit board about .5cm. Look at the audio jack, the tab on the circuit board on the bottom right is the left channel audio. You can try to reflow the solder at this point on that tab using a 25W iron. It didn't work for me, but if your connector is not as bad a mine, it might work.

Step 4. Remove the solder from the 4 tabs holding the audio jack to the circuit board. Remove the audio jack from the circuit board (this is hard and accompanied by much cursing). Try not to overheat the board and lift the lands. Use a pliers to pull out the contact for the left audio channel and bend the jack contact out 1mm or so. Insert it back into the audio jack. Get your audio cord, plug it into the jack and check and see if you have continuity with an ohmmeter. If it all checks out, continue on.

Step 5. Resolder the audio jack back into the circuit board (also accompanied by much cursing). Screw the circuit board down. Put the battery back in and see if everything still works. If it doesn't, check to see if you broke the fine wires just above the audio jack on the circuit board. They run to the other earpiece through the headset.

Step 6. Reassemble everything and see if it still works. If it does, then congratulations and enjoy your restored audio. If not, open it back up and look for broken wires.

Disclaimer: This solution will likely destroy your headset. Proceed only if you have experience working with modern surface mount parts. I am an electrical engineer with 30 years experience in troubleshooting and repairing electronics and it still was not an easy fix. Total time to repair was about 4 hours.

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Problem with Headphones


Can you pls add a few more details:
1. are the 2.5mm jacks stereo (3 pins) or mono (2 pins):
2. is your universal headset monaural or stereo; and
3. originally, did the universal headset came with 2 separate plugs?

At most that I can give you is a general/generic idea. The external speaker/microphone (or in your case the universal headset) uses also the charge jack, chances are that it is a multi terminal/pin jack. Pls refer to the diagram below.


The reason it is in continuous transmit is because one of the mini speaker is wired to the PTT trigger or the pins are wired wrong;

This would also explain why no transmit audio either manual or via VOX.

Hope this be of some help/idea. Post back how things turned up or should you need additional information.

Good luck and kind regards.

Nov 02, 2007 | Radio Communications

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