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. This may be an out of left field question, but I have a new MB but windows is not working on it due to validation problems. So until I get it resolved I was wondering if I could use the board without any components on it to charge the battery. I mean can I plug in the ac adapter and then hook in the battery will it charge. I know this is a wierd question, but there is a lot of history behind this. Thank you for any help you can give.

  2. This is probably the best tip on this site. I keep seeing mostly Gateways that have this problem, but I’ve also seen Toshiba’s with a ripped out connection.

  3. Lane Brubaker

    This repair worked great, I did how ever pull out the sleeve and did not want to attempt the fortification so instead I scaped off a lttle bit of the board on both sides and cleaned the area up. Then after I soldered the other pins on, I kind of pushed the positive pin as close to the edge as possible and used a nice amount of solder. Has been working good so far. Also, Radioshack sells a nice de-soldering tool, it’s a combination soldering iron with a bulb type suction tool built in on top. This really saved me some time compared to the traditional type

  4. cj2600

    Dustin,

    what’s the reasoning behind scraping off the green varnishing and applying a coat of solder in it’s place?

    To make a better contact between the power jack and motherboard. To make the connection stronger.

  5. Dustin

    I hate to ask such a simple question, but what’s the reasoning behind scraping off the green varnishing and applying a coat of solder in it’s place?

  6. junk_signup

    First let me say this site has been wonderful. This is the 2nd DC Jack I have replaced. The first went perfect but this one did not. I followed the instructions on how to fortify damaged power jack connection in a laptop but ran into 1 issue that I think is causing my overall problem now.

    After scraping the board, I tried and tried but could not get a fresh coat of solder on the board. How do you get solder to stick to the motherboard? It just wouldn’t adhere to the board.

    So I thought if I put enough solder on “+” terminal extension it would seal properly. I finished and put the laptop back together. Now when I plug the power up to it, the adapter’s green light goes off and it beeps. Unplug from the computer and the adapter stops beeping and the light turns back green.

    I’m assuming this Is a grounding issue.

    So, my 2 questions are:
    1 – How to you get solder to adhere to the motherboard?
    2 – What is causing the adapter to act like this?

    Again thank you

  7. Bodinator,

    Could you do a quick post about what you’ve got in your soldering kit? Like just a picture of the stuff on a towel and a description of what each item is?

    I’ve done it already in this post: DC power jack repair guide. Do-it-yourself instructions.

  8. Bobinator

    Could you do a quick post about what you’ve got in your soldering kit? Like just a picture of the stuff on a towel and a description of what each item is? I’m looking to get one and I can’t find any guide’s around about what to get/what to look for, etc.

    I’m a laptop tech, most of this stuff I know but the soldering I never quite got the hang of.

  9. Peter Caines,
    Thank you for the instructions. Really good advice.

  10. EASIER WAY — PLEASE READ

    There is a much easier way to repair the dc socket if the copper sleeve has come off –

    All you need to do is order a small sheet of copper from ebay for a few pound.

    then with the copper sheet cut a small piece 8mm / 4mm

    then use you finger and thumb to roll it into a small tube that will fit on the dc pin where the copper sleeve came of

    once on solder the copper tude to the dc socket at the end nearest to the plastic part of the dc plug so the copper tube does not slide on the pin

    once secured use some pliers and gently press the copper sleeve around the dc pin.

    once happy solder the dc power jack back on to the mother board.

    Hope you understand the instructions as it got me out of a pickle.

    Any comments or advice email me at pcaines_AT_yahoo.com

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