How to Remove a Headset Mini Jack That Broke Off Inside the Unit

Written by marshal m. rosenthal
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A mini-jack audio adaptor is connected to a headset by a cable. The plug of a mini-jack audio adaptor that has broken off inside the audio port of a portable unit (such as an MP3 player) must be removed and replaced if the unit is to continue being used. A few specialised tools from a hobby shop are all that is needed, and a work area equipped with bright task lamp.

Skill level:

Things you need

  • Magnifying glass
  • Phillips jeweller's screwdriver, size #000
  • Tweezers
  • Needle-nose pliers
  • Compressed air

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  1. 1

    Remove the battery cover from the unit if the battery compartment is accessible to the user. Remove the battery from inside the compartment if it is possible to do so.

  2. 2

    Stand the unit on a work surface with the audio port facing up. Rotate the unit so that the audio port is facing you.

  3. 3

    Move the base of the magnifying glass directly behind the unit. Adjust the gooseneck to which the magnifying glass is attached so that it is directly over the audio port.

  4. 4

    Hold the unit steady by pushing down on the top with one hand. Look through the magnifying glass as you insert the tip of the jeweller's Phillips screwdriver into the audio port.

  5. 5

    Press the tip against the inside of the audio port. Lift up on the tip while maintaining pressure against the side of the audio port. Repeat this procedure as many times as needed until you can see that the upper rim of the broken mini-jack audio plug is even with the top of the audio port.

  6. 6

    Grip the edge of the mini-jack audio plug with the tweezers. Pull up slowly on the tweezers. Stop pulling on the tweezers when the edge of the mini-jack audio plug has left the audio port.

  7. 7

    Grip the exposed edge of the mini-jack audio plug with the needle-nose pliers. Pull the mini-jack audio plug out of the audio port with a single motion. Dispose of the mini-jack audio plug in the trash.

  8. 8

    Hold the unit upside down. Hit the audio port with a burst of compressed air. Reinsert the battery into the battery compartment and close the battery cover if they were removed earlier.

Tips and warnings

  • Plastic-tipped tweezers are less likely to scratch the top of the unit when they are inserted into the audio port.
  • The mini-jack plug audio part can be acquired from an electronics supplier or, in some cases, from a local hobby shop. It can then replace the broken one after some soldering work is done between it and the cable.

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