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 website has been very informative.

    I have my 5 months old Gateway NV59 laptop which fell down landing on the power port with adapter in. It was charging for about a month after that in a certain angle only and finally stopped doing so a week back. When I looked at it the pin that is supposed to be in the middle of the port is floating inside, clearly broken.

    I have read the procedure but with the soldering/unsoldering on multi-layered mother board I am not going to attempt it myself. What are my choices — who will be able to repair these at the board level, rather than replace the entire mother board which ofcourse will be very expensive.

    Thanks so much for the information and any help in advance,

    regards,
    ~ Ram

  2. Tony,

    Hi I have hp dv6-1053cl power jack need to be replace, i remove jack from cable and solder new jack in but still not work,can you give me diagram for it.

    Why did you solder a new jack? I believe in a HP Pavilion dv6 notebook the DC is attached to a power cable. If the jack fails, you just unplug the entire power cable with just and replace it with a new cable. If you do that, you don’t have to solder anything and there will be no mistake.
    A new HP Pavilion dv6 cable is not expensive.

  3. Hi I have hp dv6-1053cl power jack need to be replace, i remove jack from cable and solder new jack in but still not work,can you give me diagram for it.thank.

  4. For those of you looking for help, the article plainly says that if you don’t feel comfortable working with solder you should not try this. Motherboards have more than just the two layers you see. there can be as many as 6 layers sandwiched into the board. This repair trick will only work if the plated through hole(that is what they are called) you pulled out isn’t internally connected to another layer of the board, and there is no easy way to check that without an x-ray. The cause of pull out is too much heat for too long. Also, look into a solder sucker with an antistatic tip and a metal plunger that wont break after a few thousand uses.

    If you break a component on the board, you need to replace it. Learn how to use a Volt-Ohm Meter to test components.

  5. Just getting my feet wet replacing the DC power jack and bought a couple old toshibas A35s to practice with.

    On your pictures you show the DC power jack with 6 points that are soldered. I understand the positive terminal and the copper bushing. I am assuming the center metal post is the negative and wonder does this also needs a copper contact point?

    On the 2 outside tabs on each side, are these strictly for securing the tabs to the motherboard or do they serve a purpose?

    I noticed playing and learning how to solder the DC power jack, when removing a jack there are also copper inserts that have come out.. is there purpose for tese or just for the DC power jack to have something to solder to for hold down?

    I like your site and it is the best information site I have found on the internet.

  6. I have done this as well and your guide on how to repair a DC jack is spot on and I actually got some good tips just by reading this article, so thanks! Now I will be using alcohol to clean the system and that pump gun for desoldering. All great idea’s.

  7. Enrique,

    mi duda es la siguiente, tengo una portátil toshiba a205 y hace un tiempo atrás tiene el problema de que no prende si le conecto el cargador. solo prende con la batería ya cargada. Gracias espero su ayuda

    Can you test AC adapter with a voltmeter? Make sure the adapter outputs correct voltage. If not, try replacing the adapter.

  8. Hola amigos. mi duda es la siguiente, tengo una portátil toshiba a205 y hace un tiempo atrás tiene el problema de que no prende si le conecto el cargador. solo prende con la batería ya cargada. Gracias espero su ayuda

  9. Techbox

    All I can say is THANKS! This fortifying worked like a charm!!!

  10. elizabeth

    hey i got a compaq laptop only had it for a year and when i plug in the charger it says its plugged in but wont charge and i got a new charger so what do i do to fix it i really dont want to buy another plzz help thanx

Leave a Reply