Speaker wire plug repair

[Jboulukos]

Hello,
I’m trying to fix the speaker wire connection for my Sanyo Boombox. I noticed the wires being loose inside the female end. This was different that the other plugs where the wires were not moving within the plug. loss of treble and bass occurred. Moving the wires either randomly made it worse or better. I was given advice to take out the wires and bend the ends of the wires to contact the posts better. I did it and now I have no sound output from the speakers, just bass from the subwoofer. Can someone direct me on how to fix this plug? It seems like it should be an easy fix but it hasn’t been so far.

 

[hopey]

it might be required to access the back of the PCB and re-sweat the pins.

 

[Jboulukos]

it might be required to access the back of the PCB and re-sweat the pins.

I checked this. The solder seems intact. It was all working well 2 days ago. Then the wires inside the female end were loose and the speaker output changed if the wires were slightly moved manually as if they were losing contact. Is there a way to make the wires not move within the female end plug housing? They rotate slightly and go up and down. I think this is the issue since none of the other plugs have the wires loose inside them. It worsened when I was advised to bend the wire ends to make better contact with the posts. Again, seems like an easy fix. I just don’t know what can be done. This particular plug seems loose and the wires are not stable inside.

 

[Jboulukos]

it might be required to access the back of the PCB and re-sweat the pins.

I think I will resolder the four joints. One of the wires has a tab off and is very loose. Is there any way to keep it in the plug? Electrical tape?

 

[caution]

If you don't feel like messing around with the sleeves in the plug, You could always add a slight bend to the pins on the board. It will take a little more force to plug in, but that will be because it's rubbing against the sleeves in the plug and making a solid connection.

 

[Superduper]

None of the wires should be soldered, they should be crimped onto a female terminal. Wires are crimped instead of soldered because solder stiffens stranded wires which causes them to eventually break at the junction where the solder stops. It seems like they are loose because they've been worked too many times. Most likely, the terminals themselves have expanded and no longer grip the pins tightly. Also, the terminals go into the plastic housing and a tang prevents the wires from pulling back out. If that tang is broken or damaged when the terminal was "de-pinned", it won't hold and will easily back out of the housing. The proper way to repair this is to replace the crimp terminals. They do sell the terminals but there are like 10 zillion varieties so you'll have to weed through many in your search. Also you need a proper crimping tool. The iwiss sn-2549 is probably the one you want, but practice first. It's easy to mess up the first few. Alternately, if you can not find the correct type of connector/pins, you can simply replace it with a different variety. As long as the male and female ends match, you are good to go. If I'm not mistaken, that is a 4-pin molex with fairly standard 0.100 spacing, but I'm just going by picture.

 

[floyd]

you can pull the wires out of that plug in if you find the right prong and just use a PIN to pry up on it and then pull the wire out. I just tried it on some spare plugs I had laying around and it seemed pretty simple much easier than I thought it would be.

 

[Superduper]

This is what you need to fix.

The terminals

2.54mm KF2510 Connector Sets 2-10Pin Housing + Header + Crimps (Molex KK Style) | eBay

Find many great new & used options and get the best deals for 2.54mm KF2510 Connector Sets 2-10Pin Housing + Header + Crimps (Molex KK Style) at the best online prices at eBay! Free shipping for many products!

www.ebay.com

The crimper

IWISS SN-2549 Ratcheting Crimping Tool 0.08-1.0 mm ² 18-28AWG for | eBay

IWISS was founded in 1990 as a family owned crimping tool manufacturer. ABOUT IWISS. The components of the ratchet crimping are made of special steel. -Due to best handle grasping position,light and compact structure and handle design ensure perfect crimping effect.

www.ebay.com

 

[Jboulukos]

Great info everyone. So I sucked out the old solder from the backside and then resoldered the 4 pins. I then tried to get the speakers to work by placing each wire onto each pin. I could only get the left channel working with the manual contact For a moment. Then nothing. Just the subwoofer functions. If I’m making metal to metal contact and it’s not working, what can be the issue?
Any advice prior to obtaining new pins and a crimper and female wire ends? I’d rather not spend a bunch on this.

 

[Superduper]

What model Sanyo is this?

 

[BoomboxLover48]

Check the wire traces on the back side of the PC board leading to each pin. There must be some crack somewhere where you might need to reflow the solder joints. Just a thought! Other members will have better suggestions.

 

[hopey]

Headphone socket

 

[Jboulukos]

What model Sanyo is this?

M-x960k

 

[Jboulukos]

Check the wire traces on the back side of the PC board leading to each pin. There must be some crack somewhere where you might need to reflow the solder joints. Just a thought! Other members will have better suggestions.

Thank you. I’ll check that. I’ll follow the wire traces on the board. Fantastic

 

[Jboulukos]

Headphone socket

Thank you. Elaborate. What should I do? Clean it? Explain and I’ll do my best to fix it.

 

[hopey]

It just something to rule out. The output to the speakers is isolated when you insert headphones, these contacts can be bridged to ensure you have no high resistance joints in the speaker circuit.

 

[Jboulukos]

It just something to rule out. The output to the speakers is isolated when you insert headphones, these contacts can be bridged to ensure you have no high resistance joints in the speaker circuit.

Ok, so I pushed this large headphone plug into the “phones” hole having 1 channel hooked up as shown and can hear the channel working (more treble and mid). Was it dirty? Stuck together? What should I do?

 

[Jboulukos]

It just something to rule out. The output to the speakers is isolated when you insert headphones, these contacts can be bridged to ensure you have no high resistance joints in the speaker circuit.

fixed. Now I can listen to LPs through the phono/line-in. Full sound. All I did was push in the headphone and pull it out. It barely fit, I had to jam it in and then pull hard to get it out. And that’s all it took for the damn speakers to function. The subwoofer worked the entire time, just the R and L speaker sets stopped and now they function. I then checked the tape volume to see if this was tied in but it still is super low at full volume. I was crossing my fingers hoping the tape volume was cured too! No dice. But I’ll take this random victory. The sound of the Sanyo M-x960k is much superior to the Sanyo M-x650k. Thanks for all the help. I have no idea why the headphone jack was the cause but it seems like so many things within these boxes rely on the function of all aspects of the machine… Example: everyone always says to spray the crap out of the record bar and the function switch as a common fix to many issues. I’m thankful for all the expert advice here even though I’m slightly above novice level. Keep rock alive.

 

[floyd]

I can tell you this if the headphone jack does not get used regularly the contacts will oxidize and when this happens you get intermittent contact. I would have never thought that was the problem with this box being that you started out thinking it was a bad plug to the speakers. on my boxes I generally plug in a headphone plug and spin it around a few times and that cleans it up enough for clear sound to come out. I'm not trying to sound like Mr Spock after the problems been solved but I do encounter this problem a lot with my old raggedy boxes. I'm too lazy to even work on boxes anymore if they act up I beat on them and pound on them and push buttons until they sound right or just put some b**** away.

 

[floyd]

the one image of the boombox that will always stay with me is the time I walked upon a pyramid of 30 brand new sanyo Big Ben stacked up just like a pyramid back then they just unloaded them off the van stack them up and sold them where they sat at the swap meets and other places. I was a fair distance away but I could tell it was some kind of big bad ass radio at the top of the stack that was out of the box the rest were stacked up in the box. turned out to be a Big Ben .