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Old 09-12-2011, 09:07 PM
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derf derf is offline
Join Date: Jun 2007
Location: Montréal, QC, Canada
Posts: 406
Default Sennheiser HD 202 detachable cable mod

It's been a long while since I came here (the forum software says a year and a half), but I thought I'd share my headphone mod here.

The left side of my Sennheiser HD 202 stopped working a while ago. At first I tought it was the plug, but while playing with the cables, I realized it was the cable going in the earpiece. I thought about replacing the whole cable (I didn't want to shorten it between the Y and the earpiece), so I decided to make a detachable cable instead. Here is how I did it.

  1. Remove the pad from the earpiece.
  2. Remove the four screws and open the earpiece.
  3. Remove the small metal bracket that olds the cable in place.
  4. Cut the cable above and below the strain relief.
  5. Carefully strip the cables.
  6. Solder the plugs. In my headphones, the red wire is the right signal, the green wire is the left signal and the copper wire is the ground. The wires are coated so they need to be heated for the solder to adhere and make a good contact.
  7. Screw the nut on the plug with the metal bracket.
  8. Remove the metal bracket, insert the plug and put the metal bracket back. I had to enlarge the hole with a 1/4" drill bit and I had to file the corners of the plug for it to fit correctly.
  9. I had to file the bottom of the earpiece for the jack to go in fully.
  10. Assemble everything and you're done!

Total cost of the project: under 2$!
I got the parts from (near where I live)
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