iFixit

With the iPod opening tool, gently lift the brown tab of the headphone ribbon cable connector. The tab will rotate up 90 degrees, releasing the ribbon cable.

Using your fingers, pull out the headphone jack ribbon cable.

The front and back of the iPod should now be completely separated.

Be careful not to damage any of the headphone or battery ribbon cables while performing this step.

Insert an iPod opening tool in between the metal case and battery at the location illustrated by the picture.

Gently wiggle the tool while pushing it further in between the battery and back case. The adhesive holding the battery should give, allowing the battery to be removed from the rear panel.

Be very careful when performing this step, since the orange ribbon cables can easily be broken.

Peel off the tape holding the ribbon cables in place.

Remove the two black Phillips screws that are securing the headphone jack to the lower casing.

Remove the following two screws:

• One black Phillips screw securing the hold switch near the corner of the iPod.
• One silver Phillips screw securing the other side of the hold switch.
• Side Note: When reassembling the iPod, a touch of white Elmer's glue on the end of your screwdriver helps hold these little screws on your screwdriver to make it easier to screw them in.

Lift the Hold switch free of its housing on the rear panel.

Slide the headphone jack out of its housing on the rear panel.

Lift the headphone jack and hold switch assembly out of the iPod.

If your replacement headphone jack includes the white plastic hold switch, simply reinstall the headphone jack. If your replacement part does not include the plastic hold switch, follow the next steps to transfer the plastic hold switch to your new headphone jack.

If you're just trying to remove the rear panel, you can skip Steps 15 and 16.

Remove the single Phillips screw nearest to the hold switch. Note: You may find adhesive holding the back of the screw in place.

Lift the plastic portion of the Hold switch away from the orange ribbon cable.

Ensure that the black notch lines up with the gray slider during reassembly of the switch (see picture 2).