Koss headphones - wire broke near jack... Any way to fix it?

[Jaichim24]

So, has this happend to anyone, where the wire at the base of the jack breaks? Ironically the thicker reinforced section that is supposed to allow it to bend and flex is where it broke. I can wiggle it and still get sound, but while I'm moving my head digging my plugs I eventually I move the wire so I don't have sound.

Has anyone gone through the trouble of splicing on a new jack to their headphones? Any links or how to's out there? Now is really not a good time for me to have to make a metal detecting purchase, but having working headphones is a must, so I'd like to fix the situation as cheaply as possible.

Thanks,

Jai

 

[Erik in NJ]

Hi, You should be able to just buy a new jack at Radio Shack or look on-line for a commercial grade jack. They are pretty easy to replace. You may want to consider upgrading the headphones to Gray Ghost NDT (No Down Time) - with those you simply replace the cord and jack at the same time - it disconnects from the headphones.

 

[Jaichim24]

Thanks for the response Erik. I did take a look at Radio Shack. The only thing I could do would be to buy a cord extension, and then cut off the end and splice it onto mine. I didn't see a 1/4" stereo jack that had some sort of wire splice adapter on it. Perhaps on-line.

 

[TONE JUNKY]

Yes, I've had to repair mine, also. I actually bought a new set of headphones, (Black Widows), but, later on, I decided to have the Koss phones repaired. I also looked for the proper jack & had difficulty finding it. I thought the price for repairs was ridiculous, ($30), still cheaper than a new set & now I have a spare.

HH

 

[Derrelld]

I got mine from Radio Shack.... They had them behind the counter!!! You will need a soldering gun,, of find someone that has one! After you get it fixed take electrical tape and rap the cord real tight up next to the jack! Make it thick,, it will protect your wire I bought a new pair of sunray's, that was the first thing it did when i opened them up!!! Good Luck!1
Derrell

 

[Erik in NJ]

This should be a common stock item at Radio Shack - just as a salesperson. You'll probably have to solder it on or maybe you can find one with screw terminals. I have a bunch of them somewhere in the house - if I could put my hands on them I'd send you one for free, but after my move locating stuff around here is not easy. Try looking on-line for a mono 1/4" male phono plug - there should be some nice professional grade plugs out there.

 

[Jaichim24]

yeah, I was a bit surprised at the solution I was offered. Does anyone know the "technical" name for what I am looking for? I haven't had much luck searching Amazon using keywords like 1/4" audio jack, splice etc.

Also, should it be mono? I mean, I doubt I am receiving signals in stereo, however the jack currrently on my headphones looks to be a stereo plug. Will it matter which one I get?

Erik, is it an actual replacement jack, made to replace an old one, or would it be a new one, like from an extension where I could cut it off and attach it to my headphones?

Thanks again for your feedback, I do appreciate it.

Jai

 

[Erik in NJ]

It would be an actual jack where the base of the jack usually screws off so you can attach the wires to the jack itself. I believe you are looking for a mono 1/4" male phono jack, plug or adapter. The one that came with the headphones was molded on at the factory and needs to be cut off so that you can attach the new one - usually soldered on. Drop me a PM if I can help.

 

[Jaichim24]

I think I found what I need.

http://www.radioshack.com/product/index.jsp?productId=2103987&numProdsPerPage=60&retainProdsInSession=1

I'll just have to hope one of the Radio Shack's near me has a few. It's interesting that the gold plated, is the same price as the standard and that the stereo jacks are the same price as the mono.


I think I'm also going to look around for those plastic tubes that shrink around connections when you heat them up. I'm afraid that all the pulling etc will just yank this back out.

Thanks all for your help!

Jai

 

[Erik in NJ]

That's not the right plug - you want the mono plug (not stereo) just like it if they have it. I see it's solderless so it probably has screw terminals - hopefully it will clamp onto the headphone cord....I can't see shrink wrap helping any. A good jack will clamp onto the incoming cord sometimes with a rubber washer that gets compressed as you screw the base on.

 

[Jaichim24]

Hrmm, I think these head phones are hi-fidelity head phones packaged with the explorers. Below is a pic I found on line, and you can see that extra black line around the plug which I believe indicates it's a stereo plug. Also, the specs on line mention they are stereo headphones. I know I don't receive my signals in stereo, but I'm paranoid that either the headphones won't work if I don't get a stereo jack, or for what ever reason it won't work in the detector.

http://www.dealtime.com/xPO-Koss-KOSS-Collapsible-Stereo

Regardless, I do appreciate you taking the time to respond back Erik. I'm going to chat with the maintenance crew at work tomorrow who do a lot of electrical work to see if they can put my mind at ease.

Jai

 

[Erik in NJ]

Looks like you're right in that they're stereo headphones....I never used mine. Just make sure to put the wires in the same (right) order - there should be three of them......PM me if you're having trouble. If you have a VOM or continuity tester you can figure out the order on the old sealed plug.

 

[Big Fang Coin Biter]

I know that most of their headphones have a lifetime warranty. Not sure about these, but worth a try.
HH - BF

 

[JHM]

I tried to shorten the cord on mine. After cutting the wire I found the wires were coated with something and I couldn't solder to stick to them. I wound up using the cord from a computer mouse. I soldered it directly to the speaker and it worked fine.

 

[dewcon4414]

Listen up KOSS.... i had the same trouble and sent them 4 emails on their website with NO reply. I finally fixed mine as well like Darrell said. Really bad design so i also got a angle plug-in and havent had a problem since. Good luck if you try to contact the company. Would i buy another pair... NOPE.

 

[DanRoss]

Koss headphones sold after a certain date (I think 1987) have a lifetime warranty. You can send them with $6 for handling and they come back like new. I just had a pair of White's KW-Pro restored... broken headphone yoke, ear pads were flaking plastic, cord broken inside near plug...

Came back very quickly like new, and this was the second time I had them in for repair...

I am getting ready to send in two more sets.

 

[Jaichim24]

Interesting Dan, thanks for the info. I did take a look at the Koss website, and I could not even find Koss UR-30 headphones. I could find reviews etc for them on other websites. However, this past weekend I'm pretty sureI voided the warranty. I cut off the old 1/4" jack and put on a new one. They are working great now!

Thanks all for your responses.

Jai

 

[DanRoss]

All's well that ends well.

Just for the record, my 10 year old White's KW Pro headphones weren't on their list either. The returned pair probably didn't have any of the same parts I sent in, but despite lacking the blue lettering that said "White's KW Pro" they look identical in every wato the originals. I figure a good set of working top of the line headphones without the lettering is better than the woefully broken things I sent in with my $6. Sort of "buy a pair of Koss headphones and never buy another pair...." I have two pair of those and both had been in for major repair before. Never as much as a question from Koss... they certainly don't quibble.