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.
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.
Remove the copper sleeve from the “+” terminal on the jack.
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.
Put the lead on the “+” connector on the power jack.
Solder the lead to the power jack.
Now I’m going to modify the “+” terminal on the motherboard.
Carefully scrape off green varnish around the whole on the “+” terminal on the motherboard. You can use a small flathead screwdriver.
If the whole is not big enough for your modified DC jack, you can widen it with an awl.
As you see, the hole on the terminal is now larger. Apply a fresh coat of solder on the clear area of the trace.
Install the power jack on the motherboard. Make sure there is no gap between the jack and motherboard.
Here’s a view from the top side of the PCB.
Solder all pins except the modified “+” pin.
Now, when the power jack is secured, you can shape the lead as it shown on the picture below.
Solder the lead to the terminal. Remove excessive flux with an old tooth brush soaked in 99% alcohol.
Here’s a view from the bottom side of the motherboard.
Be very careful. Doing this modification you can damage the motherboard and make it unusable. Proceed on your own risk.
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