How to modify damaged DC jack

posted in: DC jack, Motherboard | 92

In this guide I explain how to modify damaged DC jack. While replacing the DC jack a few days ago I accidentally damaged one of the thermals on the motherboard.

I pulled out the internal copper coating (I name it a sleeve) from the inside of the “+” terminal as it shown on the picture below.



Damaged power jack connection

The the sleeve removed, it cannot be installed back. If you solder the DC jack back in place without this sleeve, it might work but the connection between the “+” lead and motherboard will not be reliable.

The following guide will help you to modify damaged DC jack terminal. This modification should work for most motherboards with soldered power jack.

Power jack removed with sleeve

Remove the copper sleeve from the “+” terminal on the jack.

Unsolder sleeve

Find a small resistor or capacitor with thin leads. Cut off one of the leads. I’m going to use it to modify the motherboard terminal.

Shape the lead as it shown on the picture below.

Power jack mounting contact

Put the lead on the “+” connector on the power jack.

Assemble power jack

Solder the lead to the power jack.

Solder mounting leg on power jack

Now I’m going to modify the “+” terminal on the motherboard.

Power jack terminals on motherboard

Carefully scrape off green varnish around the whole on the “+” terminal on the motherboard. You can use a small flathead screwdriver.

Clean terminal

If the whole is not big enough for your modified DC jack, you can widen it with an awl.

Make hole wider

As you see, the hole on the terminal is now larger. Apply a fresh coat of solder on the clear area of the trace.

Apply fresh solder on terminal

Install the power jack on the motherboard. Make sure there is no gap between the jack and motherboard.

Install power jack

Here’s a view from the top side of the PCB.

Solder all pins except the modified “+” pin.

Power jack installed

Now, when the power jack is secured, you can shape the lead as it shown on the picture below.

Solder five contacts

Solder the lead to the terminal. Remove excessive flux with an old tooth brush soaked in 99% alcohol.

Power jack installed and soldered

Here’s a view from the bottom side of the motherboard.

Power jack view from top

Be very careful. Doing this modification you can damage the motherboard and make it unusable. Proceed on your own risk.



92 Responses

  1. Thank you very much indeed for your fast ,welcome and reassuring response c/2600. I will heed the extra tip aswell.
    Old! you should see my Desktop PC !.

  2. Colin,

    if there is presently nothing wrong with any of the laptops components before I disassemble and hopefully effect a supply fault repair after I reassemble the laptop
    can I assume that I will not have lossed its memory. ie will the windows xp still be there and all files etc?

    No, will not lose anything. All files are stored on the hard dive and if this repair is done correctly, the laptop will boot as before.

    By the way, are you sure that there is a problem with the power jack?
    If your Satellite Pro 6100 will not start at all and the power LED flashes orange light, resoldereing or replacing the power jack will not fix it. Most likely it’s poor connection between motherboard/video card/power board.

  3. I think the suggested jack socket repair/ reinforcement is well executed. Before I disassemble my Toshiba SP6100 to see if my power supply interuption problem can be solved with this repair solution I would ask please — if there is presently nothing wrong with any of the laptops components before I disassemble and hopefully effect a supply fault repair after I reassemble the laptop can I assume that I will not have lossed its memory. ie will the windows xp still be there and all files etc? I am not sure if the athor of this site would answer please or any one else who would have a reply for me.

  4. Thank you very much to this information. I just replaced the DC power jack on my Gateway MX6960. The jack and the board are a little different that what you show, but, most importantly, I did pull the cooper sleeve out with the bad jack. I would have never know about it. And, because I am not an electrician and have very, very basic soldering skills, I would still be trying to figure out how to fill the hole in the board.

    Since I do not have resisters and such laying around, I used several strands of my cooper desoldering braid. I wrapped it around the positive post and soldered it in place prior to installing the jack on the board. Because of the solder, I did have to open up the hole a little. Though it took some time, and great patience, I was able to solder the cooper to the board in a similar fashion to the method you show.

    Thanks again. The info was much appreciated!

  5. well im 15 from germany and i must thank you for this information….
    NICE PAGE….

  6. Can a laptop battery be charged any other way besides through the motherboard? Is there a way to charge the battery from a power source directly to the pins on the battery? (like a charger to car battery) If i could do this I could start my dead compaq R3000 and retrieve info to external hard drive. most likely solution to this could help many users. Thank you Sherman

  7. i have a problam about compaq i connected tha ac pin my laptop light s r blinging what is is the falt

  8. This is a great tutorial. I’ve always told the customer the unit is dead when that copper sleeve comes out. Now I have a way to fix that for them. Thanks!

  9. Hi, love your tutorial and i resoldered the power jack and it works. I did a real hack job tho. I couldnt get nice clean holes so i would heat one side and push an exacto knife blade thru and wiggle the best holes that i could. Even still I had to really heat and push the jack back into the holes and I dont think I got it as close to the MB as I would of liked. But it’s working god now, but I’m wondering if I’m on borrowed time.

  10. Kloghman

    Hi.
    first off all many compliments for the site.
    I’ve found it ’cause I have a serius problem with an Aspire 9100.
    I hope you will be so gentle to try to help me.

    So …. My friends had a Power Jack problem, the electricity didn’t work
    even if the “pin jack” of the DC adapter was inserted in the motherboard.

    To bypass this problem she started to press the top of the “pin jack” in a really strong way. She was used to left three big and heavy books over the “pin jack” and in this way the battery started charging and the laptos worked also without battery.
    But after some time she had to press more, so I decided to try to repair it.

    I’ve opened the laptop and decided to take off the powerjack (it was broken the copper sleeve).
    Then I scraped off a little quantity of the green varnish around the “+”,
    and I solded a cable, bringing this out from the laptop.
    Finally I solded two new jack, one to the DC Adapter and one to the cable solded to the motherboard. (I controlled the polarity with a Tester)

    But I have a strange problem now!!!!

    Even if the electricity passes to the motherboard (I have tested with an “Electricity Tester”) the laptop doesn’t start if the battery is not inserted.
    If the battery is inserted, the laptop starts, but the battery doesn’t start charging.

    It seems like if the electricity is not working, but as I said I tested it

    I have uploaded some photos where you can see the electricity test results.
    www flickr com/photos/33223425@N06/

    I’m in your hands….
    Please, help me or I will be killed by my friend !!!!!

    PS:
    sorry for my english!!

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