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. Toshiba Satellite A 65 – S 126. i replaced the DC – jack on this motherboard. all seem to go right, as removing the old one was clean, replace with new one an that also went in clean. reassemble laptop, plug in ac power. charging led on yellow after two hours it chance to green showing charge on batter. push power on then all led’s go out. let sit to see if it reset to charge. even try unplug and re-plug in. if i removed batter an the ac led come on put bat in an it green on bat. what you think? thank’s

  2. Hey i have searched all over the weeb and cant find an answer….ur giudes r amazing by the way but none of them explain the need for the sleeve. I need to better understand what they r used for cause until this laptop repair i honestly never knew they were even there. I got this msi laptop after a user tried a self repair and the pin on the back of the jack runs into the board hole like yours above but it somehow looked different then i was used to seeing and ya its just shorted out so im pretty sure the previous owner fucked up the repair and failed to mention it but please let me know what the sleeve is ment to do that way i can better find a solution that resolves the board being shorted out. I appreciate everything done so far though! Mainly i need to know does the sleeve allow the traces in the hold to be connected or does it kinda shield them from being connected allowing the + pin to avoide contact with them and only attach to the top and bottom of the pcb and nothing in between?? Please let me know and thanks in advance for your time.

  3. Firefly

    I was trying to repair the power jack on a Dell Latitude D520 laptop (works off battery; does not recognize power jack when plugged in). I was soldering to make the connection between the power jack box and the motherboard. I ended up using some excess solder, and I used a wick to try to get the excess off, but I may have made a connection I should not have. When I try to boot the computer, it powers up (from battery), enters the “DELL” startup page, startup bar finishes all the way across, lights flicker and shuts off. I want to try to remove the power jack connection, clean up any additional solder, then try to turn it on. My question is will the laptop power up if there is no power jack connection in place? Thank you.

  4. @ Randy,

    I replace dc jack on HP ZD7000 laptop . And now when i hit the power button all the top lights flicker it wont power up . It did power up before I worked on it, This is real what do think went wrong ,,only I did notice one pole didnt have a complete connection so i scrap the green away to see cooper and add more solder to bridge it but that did nothing to improve it the lights all flicker when i press power button

    Maybe this problem is not related to the DC jack?
    You said all lights flicker and it means the laptop is getting power through the jack.
    I really cannot tell what is wrong without looking at the laptop.

  5. I replace dc jack on HP ZD7000 laptop . And now when i hit the power button all the top lights flicker it wont power up . It did power up before I worked on it, This is real what do think went wrong ,,only I did notice one pole didnt have a complete connection so i scrap the green away to see cooper and add more solder to bridge it but that did nothing to improve it the lights all flicker when i press power button. help

  6. @ Bjoern,

    i have a Toshiba m30x laptop, the dc port was broken, i have make a bridge. no is the colore of display not black, the blsck is now red. Can you help me please?

    Check the video cable connection on the motherboard. It’s possible the video cable not seated correctly. Try reseating the connection.

  7. Hello i have a Toshiba m30x laptop, the dc port was broken, i have make a bridge. no is the colore of display not black, the blsck is now red. Can you help me please? Thanks

  8. Hi, i have emachine e525, the “+” terminal and ground show continuity, if i plug in power will this burn motherboard? how can i fix this. thx in advance !

  9. Jasmin, your battery is probably dead and unable to take a charge, so try a new one.

    cj2600, thanks for the info in your article. I’ve salvaged the connections on a few damaged vias myself but they usually don’t come out looking as good or reliable as yours. The last laptop DC jack I worked on came out well, but you must admit that it’s easy to lift out the vias when the joint won’t heat up with a lower wattage iron, especially when you’re working with ground shields/planes which dissipate the heat too quickly.

  10. jasmin

    My compaq presario CQ40 is currently out of warranty. And i found that when i plug in the batteries without AC, it cannot be turn on. Only when i plug in the AC then it can be turn on. But even when i turn on, i doesn’t appear BIOS and everything was blank. One of the thing i could notice is that, the both LED white light keep on blinking after the laptop was switched on. 1st LED light is located on top of “Num lk” key, and 2nd LED light located on the side of “Caps Lock” key.
    can u help me figure out this problem.tq

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