Nov 14 2006
Job No. 11
iPod repair log.
Model:
iPod shuffle 512MB
Initial Condition:
USB connector has broken off.
Apart from this obvious damage the shuffle plays and the controls operate normally.
Action:
Opened shuffle; used a guitar pick to remove slider then slid out the insides.
USB connecting ribbon has torn in two places.
Was expecting a standard USB connector with 4 wires but this connector has an additional 5 contacts, giving a total of 9 (not sure what these extra contacts are for?). The cable running between the USB connector and the main circuit board has 10 conductors.
The USB plug has a very small circuit board inside it. The board can be removed by breaking the glue bond that holds it in place and sliding it out the back of the plug.
This is the component side.
Tested the ribbon conductors, all 10 appear to be separate channels.
It’s impossible to solder to a ribbon cable this small so I decided to remove the ribbon connector from the main circuit board and solder directly to the connectors pads. Below is the replacement ribbon soldered to the main board.
Here’s a close-up.
The original ribbon connector has 12 contacts, the first 3 of these are tied together on the ribbon. I had to add a jumper to the circuit board to keep the connector pads tied.
At the shuffle’s USB plug I soldered enamel copper wire to the ribbon connector pads (the enamel coating insulates the wires from each other).
I soldered these wires to a ribbon cable.
Then I soldered the coloured wires to the ribbon cable.
Time to test the repair,
and it works!
(actually it wasn’t that simple. Before I got to this stage I made a mistake and soldered the ribbon cable on backwards; luckily nothing blew up)
I glued the USB connector to the end of the main unit (the masking tape is temporary),
and with everything working I slid the circuit inside the shuffle’s housing (I had to trim some plastic off the back of the battery test button to make way for the new wires, but you can’t tell from the outside).
I glued the USB connector in place with supper glue.
One more test to make sure everything still works.
Report:
Replaced internal ribbon cable in shuffle.
iPod shuffle now fully functional.
Notes:
none
Component Summary:
Memory
Battery
Logic Board (removed ribbon connector and replaced with soldered cable)
USB connector (remade connector cable)
Controls
iPod has been returned.
where did you get the cables from that you replaced?
I got the ribbon cable from a broken printer, most printers have a flat plastic cable that connects the print head to the main circuit board. This was from quite an old printer, the older style cables are generally easier to solder to.
I have the same problem and your approach was great. The only problem is that I have lost a part of the ripped ribbon cable and now I don’t know which wire goes to which connector on the USB mini board could you send a pic so I can fix it? Thanks.
I have the same problem — and I’m having trouble getting the board out of the USB connector. Where did you cut/”break the glue bond” ?
I can get it out, one way or another, but I don’t want to be more destructive than necessary.
Thanks
Matt
btw very cool project.
Jeff,
I sent you some high res images, hope they help.
different Matt,
I broke the glue bond by pushing a thin scalpel blade into the front of the plug between the circuit board and the white plastic. I remember the glue made a cracking sound and then the board slid out the back of the plug.
good luck
Scott
Scott,
Can you send me some of those high res images? I have the same problem with my ipod. Thank you!
jack i have two poartable players
ipod shuffel 1 gb
samsung yep 1 gb
both have same prblem ,as i pluged them into a wrong charger
nw both are showing usb not recognised hope you help
plz rply so that i can give you a brief
Hello, can you send me the high res images? i have the same problem. I’m one of the few that still love my 1gen shuffle
Hi Scott, can i also get high res images of this project…? I just find my 1st gen shuffle broken and i guess i will try to make it back to life again… I have the same problem as yours but my usb ribbon cable connector is only just been badly folded so i can see that its cut its connecting line…
I”m not a master technician or repairmen but this quite a challenge for me whether I can fix my shuffle or not. I do need some help though. High res images and more deep instruction will be great because i find that removing ribbon connector from the main circuit board are pretty hard that i’m afraid that i will broke something.. How did you remove that part from the circuit board?
Or maybe if you dont mind can give my your email address or ym.
Thanks,
Levy
Hi Scott can you pls help me. I trying to revive my shuffle but im having a bit trouble for 10pin schematics for the enemel copper wire. I don’t want to mess the circuit board. Thanks and godbless