Introduction
The colored metal casing.
What you need
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Carefully insert an iPod opening tool in the seam between the metal casing and white plastic top.
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Lift the top bezel off the iPod. It's glued on using a mild adhesive, so some force may be required.
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Carefully insert an iPod opening tool in the seam between the metal casing and white plastic bezel.
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Lift the bottom bezel off the iPod. It's glued on using a mild adhesive, so some force may be required.
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Remove the following two screws:
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One #00 Phillips screw with a large head near the headphone jack.
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One #00 Phillips screw with a smaller head near the side of the iPod. This screw strips easily, so be sure to press down firmly on the screwdriver.
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Use a metal spudger to carefully pry the headphone jack out of the casing. DO NOT remove the headphone jack from the iPod entirely, as it is connected via a fragile ribbon connector to the click wheel.
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Slide the headphone jack out until the white plastic housing is no longer held in place by the metal casing.
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Remove the newly-revealed Phillips #00 screw from beneath the headphone jack. Be careful, this screw is easily stripped.
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Use a spudger to disconnect the headphone jack cable from the logic board. You need to gently pry the connector toward (or up, if you like, the connector is like LEGO® building blocks) the front of the iPod until it comes loose from the logic board.
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Special hint for the reassembly: Push the connector inside until it is over the corresponding connector of the logic board. Then insert a thin tool over the connector and push it down onto the logic boards connector.
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Use a spudger to push the logic board through the iPod out of the casing. The click wheel and headphone jack should remain in the iPod.
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