Each of the rubber covered cords running to each ear piece has two fine strand wire bundles inside. The right ear piece has a red colored strand and a copper colored strand. The left ear piece has a green colored strand and a copper colored strand. The wires are coated with an insulation lacquer. The lacquer burns off when you heat the wire for soldering.
Repair item: 3.5 mm stereo headphone jack, shrink tubing
Plan for strain relief:. These headphone wires can't take any tension at all. You need to crimp the black cords to the headphone jack somehow.
Slide strain relief and headphone jack housing over the over the rubber covered headphone cord.
- You need to plan a way to relieve the pulling stress on the solder joints where the two headphone cords enter your replacement headphone jack.
- Try shrink tubing if you have it.
- If you have some thermal shrink tubing, slide a piece over the headphone cord end before stripping the wires.
- Slide the headphone jack casing over the headphone cord also.
Strip each headphone cord 5/8" using the 18 gage setting of your wire stripper..
Hold each headphone cord in a "third hand" soldering assist tool and tease the green, red and copper bundles apart..I wore a 10x Magnavisor and I used a sewing needle and a bright light.
Twist the copper colored strands from both headphone cords together. They are the common ground wires. The copper colored bundle will attach to the headphone jack ground.
Apply a dab of solder to the end of each of the three bundles of wire. You will see and smell the insulating lacquer as it burns off. Keep most of the wire bundle cool.
Position the two strand headphone cord and the 3.5 mm headphone jack in the third hand soldering stand.
- Plan where you can crimp the headphone cord. Crimp it when ready.
- The green == left channel wire goes to the tip of the 3.5mm jack.
- The red==right channel wire goes to the middle of the 3.5 mm jack
- The copper colored wires go to the ground of the jack..
- Measure resistance, 31 ohms per earpiece.
- Screw the jack cover on and finish the strain relief craftsmanship.