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iPod Mini Design Flaw?

terradyn writes "Over at iPodlounge they've discovered that the iPod mini's have a major issue with their headphone jacks. It looks like the jacks connection to the main system board is extremely poorly engineered and so normal use will wear it out and cause lots of static after around 35-40 days... If any pressure on your iPod Mini results in crackling and static, you should return your iPod immediately to an Apple store for a free replacement. They're also theorizing over in the forums that the iPod Mini shortage may be a cover for this problem..." Update: 04/12 01:08 GMT by T : billybob writes "Someone in the forum thread originally linked to has posted pictures of the iPod taken apart, demonstrating the problem."

13 of 384 comments (clear)

  1. There is another flaw by PowerEdge · · Score: 5, Informative

    The Ipod Mini freezes costantly. This was supposedly fixed in pre-production but my mini and many other's mini locks up several times a day.

    1. Re:There is another flaw by in7ane · · Score: 4, Informative

      Had a similar problem on the 40 GB iPod, 'factory resetting' it with the firmware update seemed to fix the problem (firmware is reloaded, even though it's the same version). Probably a bad load of the firmware at the factory, but that's just a guess.

  2. not an uncommon problem.. by thesupraman · · Score: 5, Informative

    Well, sounds like a case of dry solder joints to me, which means the solder used to connect parts to the motherboard has not been correctly applied and/or heated, leaving it weak. Could also be a simple socket retention issue.

    The good news is that this is usually easily fixable, opening the device and re-heating the joints that connect the socket to the board, maybe also applying a little epoxy to reinforce the socket, as a little movement can agrivate the problem.

    The bad news is that if the soldering is not up to spec, the entire device could suffer from long term unreliability, especially in a device that will see constant movement and vibration, such as this..

    Possibly they have used a surface mount socket with only the solder connections to retain it, and it really needed some form of positive retention because the case is not strong enough to provide the rest - this would make it a little harder to fix by resoldering, but the theory is the same.

    After all, it's not really a DIFFICULT problem in engineering, if this problem is happening a lot then someone has REALLY dropped the ball here.

    1. Re:not an uncommon problem.. by alienw · · Score: 4, Informative

      First, solder is quite adequate to hold a headphone jack in place. If it cracks, it means it's either a bad solder joint (possibly aggravated by an improperly designed PCB or case) or a badly designed jack. Apple might have used some kind of miniaturized jack that is too small to work adequately, or they might have screwed up the case design so the jack comes under undue stress.

      Second, you can't just introduce extra assembly stages in a mass-produced design without incurring significant cost. So that's why jacks, switches, and so on are usually soldered to a circuit board.

    2. Re:not an uncommon problem.. by goodie3shoes · · Score: 5, Informative

      Sadly, this isn't a new problem. It's been around since the Walkperson debuted. The real culprit is that the 1/8"/3.5 mm jack is a POS and any force on the plug will eventually break either the solder joints themselves or the circuit-board traces (tracks in the UK) to which they connect.The person that suggested glueing the body of the jack to the board is on the right track. A more-robust jack design is needed, but that would cost more.

      --
      BSA: "Would you like a free Software Audit"? me: "No, thanks. My software is all Free".
    3. Re:not an uncommon problem.. by swv3752 · · Score: 4, Informative

      While I agree with most of your rant, I think you are a bit mistaken about ebay.

      People sell stuff that they no longer need because of upgrades. I sold a Rio300SE because I bought a newer MP3 Player thatt had more capacity and connected via USB instead of Parallel. It was still a great device though.

      Other people sell stuff because they need some money and ebay is better than a pawn shop. I picked up a Sharp Zaurus sl5500, cheap. I love it. My unit is a little scratched up, so the previous owner must have used it quite a bit. Then again one man's trash...

      --
      Just a Tuna in the Sea of Life
  3. The Cause by Raindance · · Score: 5, Informative

    The predicted cause for this is that everything inside the IPM case is connected to the case with flexible rubber-like stuff, *except* the headphone jack (which is connected rigidly- standard practice for headphone jacks but unfortunate here).

    Repeated stress on the case, then, puts stress on the headphone jack and eventually it may lead to the audio problems expressed at iPodlounge.

    This should be an extremely easy fix for future IPM revisions, and I'd imagine Apple will be taking care of their customers.

    As a sidenote, I had an iBook's logic board fail out of warranty due to a manufacturing flaw and I called Apple on I heard that Apple the flaw- they sent me a box, postage prepaid, in which to send my iBook back, repaired it, and sent it back to me. No money out of my pocket. Very cool.

  4. Re:That's what you get... by LostCluster · · Score: 4, Informative

    ...for being cheap and uber-stylish. For $50 more you could have had a regular iPod with way more storage, but noooooo, you HAD to get an Apple MP3 player in something other than white!

    If you want a 15 GB iPod in color, check these guys out. They'll even paint your existing iPod if you're willing to send it in.

  5. That's why it's called the bleeding edge... by BigFlirt · · Score: 5, Informative

    I don't know who is and who isn't aware of this rule of thumb, but working at a big Mac development house (no McDonald's jokes plz) taught me one thing. Never ever EVER (shake a baby) buy first revision Apple products. Since the beginning of time, I think Apple has looked at people who buy their newest line not as their first line of customers, but their last team of product testers.

    Nearly every Apple product that I've seen come out in the past five years, I've known someone that has to return a Revision A product because Apple just dropped the ball on one thing or another. Don't get me wrong, their products are quite amazing and I'm envious of all my Apple fanatic friends that have everything, but if you're going to be on the bleeding edge and pre-order things before Apple's even done making them, of course you're going to see something wrong with the first batch. If you think otherwise, then why don't you try to release an idiot-proof product to people that want their mp3s automagically synced from their work desktop to their iPod to their car to their laptop to their servers to their friend's computers in the UK. ("it's on my .mac account, why can't you see it on your desktop!?!?")

    ...but I ramble...

  6. Re:That's what you get... by dasmegabyte · · Score: 4, Informative

    I bought an iSkin EXO2. It's a plastic shell that wraps tightly around your ipod. Provides a better belt clip, screen protection and impact protection while making your ipod look less like an ipod, without increasing the size too much.

    Way cheaper than a custom paint job...and less troublesome if you drop it!

    --
    Hey freaks: now you're ju
  7. Warranty? by Meneudo · · Score: 4, Informative

    As with all products, no matter who makes them, you should probably buy a warranty if none is provided. Fortuantly, all Apple hardware products come with a one-year limited warranty against defects. So before you flame, remember that your product is probably in warranty, and that Apple would be more than happy to replace it because they desire your business.

    --
    ...
  8. Re:That's what you get... by SatanicLoveMonkey · · Score: 5, Informative

    Also cool: ipodmods.com

    They'll replace your LEDs or change the LCD backlight color...

    --
    If you think you can hurt me again, you're wrong. I left my heart in my other pants.
  9. Re:iPod engineering by SchnauzerGuy · · Score: 5, Informative

    For a more accurate battery guage, create an empty file called "_show_voltage" (no quotes) in iPod_Control\Device.

    For 3G iPods with the latest firmware, this will cause the default battery meter to be replaced with a digital voltage display, in 1/10th volts. So a fully charged iPod might display 500 (5.00V), while a nearly dead iPod will be under 200 (2.00V).