The most common reason for headphones to stop working is because one or more wires have become disconnected inside the cable. To fix this problem, you need a small screwdriver, wire cutters, a craft knife, insulating tape, soldering iron and solder. You must locate the break and solder the pieces together to repair the error before reinsulating the piece.
- Locate the break in the lead
If wires have disconnected, the lead has a break in it. Use your fingers to feel the cable; a kink in the cable indicates a disconnected wire. Make sure that the headphones are not connected as you begin to work with it.
- Cut open the lead insulation
Using wire cutters, carefully cut open the insulation where the break occurs without cutting through the wires. This allows you to see the wires.
- Find the broken wires
Once you cut open the insulation, you can see the wires within it. Broken wires are ones that have become disconnected, resulting in a space within the length of the wire. Confirm which wire or wires have broken.
- Strip the ends of the wire
Before fixing the wire, carefully strip the rest of the insulation off of the ends with wire cutters. This reveals the bare metal.
- Solder the wire back together
Use the solder iron to heat the solder. Use the solder to rejoin the two pieces of the broken wire.
- Wrap insulating tape
After fixing the wire, wrap insulating tape around the rejoined ends. Keep wrapping insulating tape a few inches up the lead to ensure stability and prevent further damage.