Mark or note the edges that need to be cut to open the AirPort Express case.

Use a dremel tool with a thin cutting bit to slowly cut around the marked edges. Cut evenly along the middle of the edges, and make several shallow passes to ensure that you don't accidentally cut into any of the components inside.

• If you see sparks while cutting, it means you are cutting through the EMI shields. Reduce your cutting depth immediately to prevent further damage.
• Be especially cautious when cutting next to the LED light, as the power wires are right next to the case wall. The wires are highlighted in orange in the third picture. Severing these wires may make the repair extremely difficult.

Use a metal spudger or prying device to begin levering the case halves apart.

Do not push the prying device too far into the case, as this could damage the EMI shields or other components.

The case will be most stubborn near the grey power inlet, as this piece is glued to the case halves. Focus on separating the other parts of the case first.

Once the case halves are loose, use your hands to pry open the case.

• Do not attempt to separate the case halves as there are wires still joining them.

Trace the red, orange and black power wires to their connector on the power supply.

Disconnect the power cables from the power supply.

Remove the grey power inlet from the case half it is still attached to. Use a pair of pliers to rock the power inlet back and forth until it breaks free from the glue.

Finish separating the case halves.

The power supply is attached to the upper case half with one 5.38 mm Phillips screw.

Use a #1 Phillips screwdriver to remove the screw and then remove the power supply.

• Do not lose this screw. You will be using it to secure the new power supply to the upper case half.

The printed circuit board (PCB) supplied in your kit can be soldered using any rails that you desire. However, we have determined that using the following rails provides a nice, low-profile, fit.

• Ground
• 5V
• 3.3V
• "Adjust"

The following are the suggested hole locations for components, though they can be placed in any hole along the proper traces.

• .1 µF Capacitor
• 1 µF Capacitor
• 240 Ω Resistor
• 390 Ω Resistor
• Voltage Regulator Pin 1
• Voltage Regulator Pin 2
• Voltage Regulator Pin 3

The power inlet and outlet wires are recommended to be soldered in the following locations, though again they can be soldered to any through-hole you desire along the proper trace.

• Power Supply +
• Power Supply -
• 5 V Out
• 3.3 V Out
• Ground Out