Mac iBook G4 Power Adapter DC Plug Repair Howto Guide

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(Mac iBook G4 Power Adapter DC Plug Repair Howto Guide)
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  Contacts will have to be prepared to fit the printed circuit board (PCB). Cut a bit away from the S (sleeve) and the R (ring) contacts and connect wires for T (tip) and R (ring). <br /><br /><br /><br /><br /><br />
 
  Contacts will have to be prepared to fit the printed circuit board (PCB). Cut a bit away from the S (sleeve) and the R (ring) contacts and connect wires for T (tip) and R (ring). <br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_373.jpg [[Image:apple_ibook_charger_connector_repair_373_thumb.jpg]]]  After estimated the correct length, connect to the appropriate holes of the PCB. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_373.jpeg|thumb|right|150px]]
 +
  After estimated the correct length, connect to the appropriate holes of the PCB.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_376.jpg [[Image:apple_ibook_charger_connector_repair_376_thumb.jpg]]]  So it looks from the other side. Please note the solder securing the S contact. Without that lots of new TRS jacks are unusable. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_376.jpeg|thumb|right|150px]]   
 +
So it looks from the other side. Please note the solder securing the S contact. Without that lots of new TRS jacks are unusable.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_378.jpg [[Image:apple_ibook_charger_connector_repair_378_thumb.jpg]]]  The outer shield in its original shape would short circuit TRS contacts, remove some of it. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_378.jpeg|thumb|right|150px]]
 +
  The outer shield in its original shape would short circuit TRS contacts, remove some of it.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_380.jpg [[Image:apple_ibook_charger_connector_repair_380_thumb.jpg]]]  For a first test of what we have done use a piece of tubing to isolate the outer shield and connect the wires. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_380.jpeg|thumb|right|150px]]   
 +
For a first test of what we have done use a piece of tubing to isolate the outer shield and connect the wires.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_383.jpg [[Image:apple_ibook_charger_connector_repair_383_thumb.jpg]]]  For the shield soldering is not necessary to do this test. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_383.jpeg|thumb|right|150px]]   
 +
For the shield soldering is not necessary to do this test.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_386.jpg [[Image:apple_ibook_charger_connector_repair_386_thumb.jpg]]]  These are the connections in the plug I have seen. YMMV! <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_386.jpeg|thumb|right|150px]]   
 +
These are the connections in the plug I have seen. YMMV!  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_390.jpg [[Image:apple_ibook_charger_connector_repair_390_thumb.jpg]]]  If you all survived the test it's time for putting the connector together. First spend some epoxy glue for isolation. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_390.jpeg|thumb|right|150px]]   
 +
If you all survived the test it's time for putting the connector together. First spend some epoxy glue for isolation.  
 +
<br /><br /><br /><br /><br /><br />
  
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_393.jpg [[Image:apple_ibook_charger_connector_repair_393_thumb.jpg]]]  Smoothing the light guide's gash provides some room for the glue afterwards. <br /><br /><br /><br /><br /><br />
+
[[file:Apple_ibook_charger_connector_repair_393.jpeg|thumb|right|150px]]   
 +
Smoothing the light guide's gash provides some room for the glue afterwards.  
 +
<br /><br /><br /><br /><br /><br />
  
 
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_396.jpg [[Image:apple_ibook_charger_connector_repair_396_thumb.jpg]]]  The shield should be glued to the TRS jack, again epoxy is used. Don't forget to solder the pin in the PCB. <br /><br /><br /><br /><br /><br />
 
[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_396.jpg [[Image:apple_ibook_charger_connector_repair_396_thumb.jpg]]]  The shield should be glued to the TRS jack, again epoxy is used. Don't forget to solder the pin in the PCB. <br /><br /><br /><br /><br /><br />

Revision as of 08:28, 12 June 2012

Mac iBook G4 Power Adapter DC Plug Repair Howto Guide

How to revive a broken charger connector belonging to a pretty girl's apple?



Apple ibook charger connector repair 335.jpeg

Yes, many pretty girls are fond of apples. And they like dancing. When her nice feet stepped on the cable her Mac practiced flying, fortunately almost without further consequences. But the charge plug did not fit any more. The golden tip of the sophisticated connector even preferred to remain inside of the Mac and was not easily be convinced to leave. What's to be done now?





Apple ibook charger connector repair 337.jpeg

Let's start with some surgery ...





Apple ibook charger connector repair 340.jpeg

... till ...





Apple ibook charger connector repair 343.jpeg

  the white shell could be removed. As suspected from the charging light toy effects before, there are some electronics inside.





[file:Apple_ibook_charger_connector_repair_346.jpeg|thumb|right|150px]]  The cable had two wires, the black one ending next to some semiconductor, the grey one between two resistors. Removed the cable.





[file:Apple_ibook_charger_connector_repair_348.jpeg|thumb|right|150px]]  bk = black





right150px
  gr = grey







Probably we shouldn't mix this up later on.

Apple ibook charger connector repair 351.jpeg
 

Formerly, the inner contacts of the connector must have looked very similar to a simple 2.5mm TRS (tip-ring-sleeve) jack. Here I have pulled the damaged parts out.





Apple ibook charger connector repair 353.jpeg

  The shield should be readjusted to some cylindrical shape.





[file:Apple_ibook_charger_connector_repair_355.jpeg|thumb|right|150px]]   To have a look at the inner parts, the light guide will have to be removed. Slice it.





Apple ibook charger connector repair 358.jpeg

  Slide it away.





Apple ibook charger connector repair 361.jpeg

  To remove the shield it should be dilated.





Apple ibook charger connector repair 364.jpeg

  And don't forget desoldering.





Apple ibook charger connector repair 365.jpeg

  The replacement TRS jack is not gold plated like the delicate original but it seems quite robust.





Apple ibook charger connector repair 367.jpeg

  To prepare it the terminals should be tinned using some acid flux. And the usual weak internal connections in this type of TRS jack can be secured by soldering. Be quick enough not to melt the plastic rings in the tip.





Apple ibook charger connector repair 369.jpeg

  Contacts will have to be prepared to fit the printed circuit board (PCB). Cut a bit away from the S (sleeve) and the R (ring) contacts and connect wires for T (tip) and R (ring).





Apple ibook charger connector repair 373.jpeg

  After estimated the correct length, connect to the appropriate holes of the PCB.





Apple ibook charger connector repair 376.jpeg
 

So it looks from the other side. Please note the solder securing the S contact. Without that lots of new TRS jacks are unusable.





Apple ibook charger connector repair 378.jpeg

  The outer shield in its original shape would short circuit TRS contacts, remove some of it.





Apple ibook charger connector repair 380.jpeg
 

For a first test of what we have done use a piece of tubing to isolate the outer shield and connect the wires.





Apple ibook charger connector repair 383.jpeg
 

For the shield soldering is not necessary to do this test.





Apple ibook charger connector repair 386.jpeg
 

These are the connections in the plug I have seen. YMMV!





Apple ibook charger connector repair 390.jpeg
 

If you all survived the test it's time for putting the connector together. First spend some epoxy glue for isolation.





Apple ibook charger connector repair 393.jpeg
 

Smoothing the light guide's gash provides some room for the glue afterwards.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_396.jpg File:Apple ibook charger connector repair 396 thumb.jpg]  The shield should be glued to the TRS jack, again epoxy is used. Don't forget to solder the pin in the PCB.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_398.jpg File:Apple ibook charger connector repair 398 thumb.jpg]  Probably this is more robust and in the next incident a corner of the Mac will be ruptured. You have been warned.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_400.jpg File:Apple ibook charger connector repair 400 thumb.jpg]  Cleaning the edges allows for an unconspicious scar.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_402.jpg File:Apple ibook charger connector repair 402 thumb.jpg]  The light guide does not fit yet.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_404.jpg File:Apple ibook charger connector repair 404 thumb.jpg]  It has to be somewhat shorter and additionally needs notches at the inner side for the sleeve and ring connections of the jack.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_410.jpg File:Apple ibook charger connector repair 410 thumb.jpg]  Use fine sandpaper before polishing.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_408.jpg File:Apple ibook charger connector repair 408 thumb.jpg]  Blue jeans make a good polishing agent for plastic parts. Using her's could help to keep the procedure less boring.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_412.jpg File:Apple ibook charger connector repair 412 thumb.jpg]  There is not plenty of room. Be careful not to perforate the insulation of the wires. The light guide's fissure will be filled with a drop of transparent epoxy glue.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_414.jpg File:Apple ibook charger connector repair 414 thumb.jpg]  Secure the wires with flexible hot glue.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_418.jpg File:Apple ibook charger connector repair 418 thumb.jpg]  The final suture, filled with epoxy glue. For cosmetics, mix some titanium dioxide with the glue.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_421.jpg File:Apple ibook charger connector repair 421 thumb.jpg]  Yes, it charges and it lights. Be careful... As I said: Next time the plug will be stronger.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_423.jpg File:Apple ibook charger connector repair 423 thumb.jpg]  Finally, check the leftovers carefully. You should exactly find these. Else you'll have to repeat the surgery.





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Disclaimer and Copyright

Warning: These instructions are given without any warranty. They don't have to be complete or correct. Don't do any of the following steps if you're not sure of what you're doing. You could damage your notebook and you WILL lose your warranty. Everything you do will be at your own risk.

All the pictures and explanations are a courtesy of an Anonymous "Surgeon". The document and the pictures are entirely put under CopyLeft.

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