Mac iBook G4 Power Adapter DC Plug Repair Howto Guide

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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





[file:Apple_ibook_charger_connector_repair_349.jpeg|thumb|right150px]]  gr = grey





Probably we shouldn't mix this up later on.

[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_351.jpg File:Apple ibook charger connector repair 351 thumb.jpg]  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.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_353.jpg File:Apple ibook charger connector repair 353 thumb.jpg]  The shield should be readjusted to some cylindrical shape.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_355.jpg File:Apple ibook charger connector repair 355 thumb.jpg]  To have a look at the inner parts, the light guide will have to be removed. Slice it.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_358.jpg File:Apple ibook charger connector repair 358 thumb.jpg]  Slide it away.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_361.jpg File:Apple ibook charger connector repair 361 thumb.jpg]  To remove the shield it should be dilated.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_364.jpg File:Apple ibook charger connector repair 364 thumb.jpg]  And don't forget desoldering.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_365.jpg File:Apple ibook charger connector repair 365 thumb.jpg]  The replacement TRS jack is not gold plated like the delicate original but it seems quite robust.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_367.jpg File:Apple ibook charger connector repair 367 thumb.jpg]  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.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_369.jpg File:Apple ibook charger connector repair 369 thumb.jpg]  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).





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_373.jpg File:Apple ibook charger connector repair 373 thumb.jpg]  After estimated the correct length, connect to the appropriate holes of the PCB.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_376.jpg File: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.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_378.jpg File:Apple ibook charger connector repair 378 thumb.jpg]  The outer shield in its original shape would short circuit TRS contacts, remove some of it.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_380.jpg File: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.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_383.jpg File:Apple ibook charger connector repair 383 thumb.jpg]  For the shield soldering is not necessary to do this test.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_386.jpg File:Apple ibook charger connector repair 386 thumb.jpg]  These are the connections in the plug I have seen. YMMV!





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_390.jpg File: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.





[contrib/apple_ibook/pics/apple_ibook_charger_connector_repair_393.jpg File:Apple ibook charger connector repair 393 thumb.jpg]  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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