DC power jack repair guide

posted in: DC jack | 524

This guide will explain how to repair a failed or loose DC power jack on a laptop computer yourself.

Disclaimer: I’ve made these instructions only for people experienced with soldering and repairing computers. If you don’t feel comfortable doing this job, please do not open the laptop or you can permanently damage your computer. Take your laptop to a professional repair shop instead.
Use this repair guide at your own risk. :)

For this repair you’ll need the following tools.

1. Soldering iron or soldering station. I use Weller WES51 soldering station and for this job I set temperature to about 800-850°F.
2. I use high-tech rosin core silver-bearing solder from Radioshack with diameter 0.022″ ( Catalog #: 64-013 ). I think standard rosin core solder will work just fine.
3. Desoldering pump for removing solder around component leads. I use Edsyn Soldapullt pump, model DS 017.
4. 99% isopropyl alcohol and tooth brush for cleaning the motherboard from flux.
5. A new DC power jack.

DC jack repair tools

Laptop DC power jack repair guide.

Laptop DC power jack

As you see on the following picture, the solder drop on the positive terminal looks different than on other three contacts. That’s where the problem is. The positive pin is not making a good contact with the motherboard and because of that power to the laptop cuts off when I move the power plug inside the power jack.
I’m going to desolder the power jack from the motherboard, clean contacts on both power jack and motherboard and then solder it back in place – this is the proper way fixing the power problem.

DC power jack bottom side

Start desoldering process with adding some new fresh solder to all three contacts. This will make old solder more flowable, easier to remove.

Removing solder

While heating one of the contacts, remove the solder from this contact using the desoldering pump. Repeat the same steps with all power jack contacts until you remove as much solder as possible.

Sucking extra solder

Grab the power jack and carefully try removing it from the motherboard. Most likely you will not be able to remove the power jack the first time because there will be some solder bridges left between the contacts and traces on the motherboard. Carefully wiggle the power jack without applying any significant force and at the same time heat up all contacts one by one. This will help you to remove the power jack.

Remove DC power jack

The DC power jack is almost removed from the motherboard.
Be careful. Inside the positive hole there is a copper sleeve which connects the terminal on one side of the motherboard with the traces on the other side. If you are removing the power jack with force, you can pull the sleeve from the hole. You don’t want to do that.

UPDATE: If you accidentally removed the internal sleeve, check out this post: How to fortify damaged power jack connection.

So, do not apply any force and make sure the solder is melted when you are removing the power jack. I hope you understand what I’m talking about.

Separating jack from motherboard

After the power jack is removed, clean all oxidized contacts with a knife.

Cleaning power jack contacts

Apply a fresh coat of solder to all contacts on the power jack.

Coating contacts

The power jack terminals will look dirty because of melted flux.

Flux on motherboard

You can remove the flux using the tooth brush and alcohol. It’s not necessary but it will make your job looking clean.

Removing extra flux

Apply a fresh coat of solder to all power jack terminals on both sides of the motherboard.

Coating contacts

This side has been coated.

Cleaned contacts side 1

And this side has been coated too.

Cleaned contacts side 2

Now you can install the power jack back on the motherboard. Put something under power jack so there is no gap between the jack and the motherboard. Now you are ready to solder the jack back in place.

DC power jack installed

Solder all power jack pins.

Soldering power jack

The job is done and the laptop DC power jack is fixed. B-E-A-utiful!
Now just install the motherboard back into the laptop and you are done.

DC power jack fixed

524 Responses

  1. I have a toshiba a105 that sparks inside the dc connector when i plug it in. The laptop will not come on and there are no lights that will come on either. My dc connector is not connected directly to the motherboard. It has four wires (two hot, two grounds) and plugs in about four inches down and to the right of connector. After I broke laptop down and removed connector I checked power with metor and it has power going through connector and does not arc off when connector is unplugged from motherboard. This leads me to believe that the dc conn. is good and it is the motherboard plug where the dc connector is plugged that is bad. Do you think that this could be the case? Any other ideas? Thanks for all the great info. Don

  2. Thanks so much. I used the same procedure to repair the power jack on an electronic keyboard – worked like a charm!

  3. My laptop won’t turn on, but the charging light is on. I’ve an HP dv6810us laptop. Before I do this, or find someone to do so, do you think this power jack on the motherboard may be the problem?

  4. David Morley

    Nice article.

    Here are a couple of tips for the desoldering problems. Those desoldering pumps have to be cleaned and greased periodically to maintain good suction. Apply a coat of silicon grease to the o-ring in the pump. I prefer soldering braid to the pumps. It is braided copper that comes in different widths, you should be able to buy it anyplace you got your solder and iron. 1/2 inch braid should work well for desoldering something like the case of these power jacks and 1/8 inch for the power pin.

  5. @ 472, Rick

    Are you serious…? Why don’t you just carefully open the laptop so you don’t have to deal with a messy looking job?

  6. my dell laptop and i conect the dc power but my power adapter lost the power

  7. nisha,

    I ordered a usb board for hp ,does it have dc jack attached to it.

    What HP laptop model you have? They all different.

  8. Here is a very simple method. I repaired 6 laptops successfully.

    You need a small(sharp)wire cutter. Unplug, disconnect battery.

    Turn the laptop over. Very carefully start cutting away the

    plastic on the bottom of the notebook near the DC jack. Cut

    out just enough plastic until you can see the broken jack

    connections. Cut a little more until you can fit a small

    soldering iron inside. Solder 2 wires to the board. 1 to the positive & 1 to the negative.(The negative wire usually can be soldered to the chassis (check with a meter).(some computers use a positive ground so you will have to check with a meter).
    Now, you are going to connect the wires to an external DC jack that you can buy at Radio Shack(take your power supply with you, to make sure it fits). Or do what I did. Take out a jack from a old appliance. (I ripped out the jack from an old cordless phone).Now solder the wires to the new jack. Check to see if it works. Tape up the wires,use electrical tape to cover the broken plastic on computer. Now find a good spot (out of the way of USB speaker jacks etc. to mount the jack. Use Epoxy to mount the new jack. (crazy glue doesn’t last). DONE!!

    I’m typing this on a computer that I fixed this way 3 years ago.(Still going strong).

  9. I ordered a usb board for hp ,does it have dc jack attached to it.

  10. Hubb,

    This is not 100% correct.
    Yes, in some Acer laptops you can unplug the DC jack harness from the motherboard and replace it with a new one without soldering.
    But in some Acer laptops the DC jack soldered directly to the motherboard and cannot be easily unplugged. It has to be desoldered.

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