Credit where it's due; I got my headphone fixed thanks to your guide. One thing I did different that would help others: -Use a plier and knife to hold and split the plastic piece that has the metal clamp down the middle, but make sure to not make the cut too deep that it'll be cut in half. This way you can reuse the plastic piece and rewrap it to another section of the wires. You really don't need to make a knot with the wires, since that plastic bit acts as a well enough brake to prevent yanking the wires out of the sautered ends.
Very helpful video. Gave me the confidence to try to repair an old pair of Sennheiser HD203s. Almost identical desdign and the same issue - one headphone working intermittently when you fiddled with the wire going into it. Your tip on using a flame to get rid of the insulation round the wires was useful. Instead of discarding the plastic sleeve round the wire where it enters the headphone, I used a sharp Stanley knife to slice it along its length and was then able to pull the old wire out and push the new one (i.e. the new bit of the original wire) into it, and push it back through the hole in the headphone. All working now. Thanks.
You didn't show removing the screws, which threw me off. I did see you put 'em back in though. Otherwise, well done! I had trouble re-soldering the connection as the fuzzy, thin wires caused very dim audio. So, I was ready to replace all the wires in the whole thing with higher-gauge A/C cord. Instead I used a match as you indicated and it worked fine, so you saved me work. For me, it was easier to remove the earphone cup by pushing it to the bottom of the headband. Looks like the track is open there for that purpose.
I just picked up two pairs of these headphones for $2 (AUD) each and one of them needs wire repair. Thanks for sharing this video. Cheers from Western Australia 🇦🇺 ✌🏻😎
I just did this repair this evening. Exact same problem. What I did is to slice that molded-on piece right up the wire. Cut off the bad section of wire under that and spliced to two wire sections back together. I soldered one wire in splice and covered it with the thinnest heat shrink tubing I have. Then soldered the other wire and covered the section with the same heat shrink. I was able to reattach that molded-on piece to the wire and also crazy glued it to the wire. The right wire is then only 3/4 " shorter than the left. Saved me from almost buying a $70 replacement....now I need some ear foams.
Thank you! The actual repair is straightforward. But knowing how to dismantle my HD202's without destroying them was great information! Also like the tip to remove the insulation with a little flame. Made soldering the wires back one of the simplest soldering jobs I've done. Thanks for sharing this video!
Very helpful video. Note that you can re-use the old strain relief gland which may make a neater job. Open the speaker shell and cut the wire at the top and bottom of the strain relief gland. Remove the gland and use a knife to cut halfway into the gland along its length. Pick out the old bits of cable. Now gently ream out the central core, starting with a small drill and working up to a 2mm drill bit. At that point the residual outer sheath of the cut cable will come out of the gland. Feed the new length of wire through the outer speaker shell and slide on the old gland. Re-assemble as normal and you may only need a small drop of superglue to re-seal the gland around the cable. If you re-terminate the cable, it will be 15cm shorter than before and you need about 12½cm of unterminated cable between the gland and the speaker.
Very helpful. After seeing this I was brave enough to take my HD 202's apart. tested for continuity to the plug which failed on 3/4. Then cut the cables just the other side of the headphone casing then used a candle to bare the end of the wire. Cleaned the ends with some sandpaper. Made my first ever use of a soldering iron. And to my surprise all is now working. ps had to solder twice as , yes, I forgot to run the cable through the headphone casing first.
Great video saved my sennheisers, very helpful tip using the lighter. I managed to save the cable restraint by using a small drill bit to enlarge just big enough for cable to slide through 👍
Got one of these on my head. Plastic completely worn off the cushions. Need to replace them now though because one of the speakers is mechanically worn out and it making all kinds of weird extra sounds with heavy bass. Deffo getting the current replacement for the 202.
Eu usei uma "mini drill bit" para remover o pedaço de cabo preso no "Strain Relief" , o qual foi reaproveitado. Talvez tenha perdido a função, mas o acabamento ficou como no original.
Credit where it's due; I got my headphone fixed thanks to your guide.
One thing I did different that would help others:
-Use a plier and knife to hold and split the plastic piece that has the metal clamp down the middle, but make sure to not make the cut too deep that it'll be cut in half. This way you can reuse the plastic piece and rewrap it to another section of the wires. You really don't need to make a knot with the wires, since that plastic bit acts as a well enough brake to prevent yanking the wires out of the sautered ends.
Yes, best answer. I Used a small and very sharp knife. Thank you
Very helpful video. Gave me the confidence to try to repair an old pair of Sennheiser HD203s. Almost identical desdign and the same issue - one headphone working intermittently when you fiddled with the wire going into it. Your tip on using a flame to get rid of the insulation round the wires was useful. Instead of discarding the plastic sleeve round the wire where it enters the headphone, I used a sharp Stanley knife to slice it along its length and was then able to pull the old wire out and push the new one (i.e. the new bit of the original wire) into it, and push it back through the hole in the headphone. All working now. Thanks.
You didn't show removing the screws, which threw me off. I did see you put 'em back in though.
Otherwise, well done! I had trouble re-soldering the connection as the fuzzy, thin wires caused very dim audio. So, I was ready to replace all the wires in the whole thing with higher-gauge A/C cord. Instead I used a match as you indicated and it worked fine, so you saved me work.
For me, it was easier to remove the earphone cup by pushing it to the bottom of the headband. Looks like the track is open there for that purpose.
I just picked up two pairs of these headphones for $2 (AUD) each and one of them needs wire repair. Thanks for sharing this video. Cheers from Western Australia 🇦🇺 ✌🏻😎
I just did this repair this evening. Exact same problem. What I did is to slice that molded-on piece right up the wire. Cut off the bad section of wire under that and spliced to two wire sections back together. I soldered one wire in splice and covered it with the thinnest heat shrink tubing I have. Then soldered the other wire and covered the section with the same heat shrink. I was able to reattach that molded-on piece to the wire and also crazy glued it to the wire. The right wire is then only 3/4 " shorter than the left. Saved me from almost buying a $70 replacement....now I need some ear foams.
Thank you! The actual repair is straightforward. But knowing how to dismantle my HD202's without destroying them was great information! Also like the tip to remove the insulation with a little flame. Made soldering the wires back one of the simplest soldering jobs I've done. Thanks for sharing this video!
Very helpful video. Note that you can re-use the old strain relief gland which may make a neater job. Open the speaker shell and cut the wire at the top and bottom of the strain relief gland. Remove the gland and use a knife to cut halfway into the gland along its length. Pick out the old bits of cable. Now gently ream out the central core, starting with a small drill and working up to a 2mm drill bit. At that point the residual outer sheath of the cut cable will come out of the gland. Feed the new length of wire through the outer speaker shell and slide on the old gland. Re-assemble as normal and you may only need a small drop of superglue to re-seal the gland around the cable. If you re-terminate the cable, it will be 15cm shorter than before and you need about 12½cm of unterminated cable between the gland and the speaker.
Very helpful. After seeing this I was brave enough to take my HD 202's apart. tested for continuity to the plug which failed on 3/4. Then cut the cables just the other side of the headphone casing then used a candle to bare the end of the wire. Cleaned the ends with some sandpaper. Made my first ever use of a soldering iron. And to my surprise all is now working. ps had to solder twice as , yes, I forgot to run the cable through the headphone casing first.
Great video saved my sennheisers, very helpful tip using the lighter. I managed to save the cable restraint by using a small drill bit to enlarge just big enough for cable to slide through 👍
Greatest tutorial on youtube about this headphone, thanks for advice :D
Sitting here watching this video whilst listening with my HD202 working in the left ear 👂 only. LOL
thanks for your video. finnaly i can fix my sennheiser after 5 years ago. really helpful.
Got one of these on my head. Plastic completely worn off the cushions. Need to replace them now though because one of the speakers is mechanically worn out and it making all kinds of weird extra sounds with heavy bass. Deffo getting the current replacement for the 202.
Very helpful video. Repaired mine in like 20 minutes. Thanks!
had same problem, just fixed after watching your tutorial, the issue was that bloody " not" thank you very much for you help, :0
SAme headphone, same problem on the same hear, same wearing on the foams :)
Me too! haha
Good job Jan. Great additional tips by all of you others ;-)
Brilliant tutorial! Had the exact same problem and managed to fix it thanks to this video, thank you very much!
Your video helped a lot, made my hd 202 with mic now after original cable failed, thank you 👍🏼
I saved a lot of money with this! thanks a lot!
the other side of my headphones broke so I used this tutorial again. Thanks again!
the cable broke again, fixing it as I write this.
Good tutorial. I fixed my headphone thanks to this video! Thank you!
Thanks to your video I could fix my Sennheiser, thank you so much...
Eu usei uma "mini drill bit" para remover o pedaço de cabo preso no "Strain Relief" , o qual foi reaproveitado. Talvez tenha perdido a função, mas o acabamento ficou como no original.
thank you dude, I have the same issue, you saved me.
Great video. I have no idea how to open it up for repair if not this video.
Thank you for the help, much appreciated!
Gracias por el video, una genialidad, en menos de 15 minutos pude usar mis 202hd después de 8 largos años jaja
Worked like a charm ... Thanks Jan... Best
Thanks, you are awesome, this fixed my headphones
Great video
всем кто мюсмторит это видео даю совет, чтобы очистить провод просто приложите к проводу паяльник с 2 сторон и резина спокойно снимется
It works for me thank u
Thank you so much
Nice great ☺️☺️☺️☺️
Thanks
Me ajudou muito! Obrigado amigo!
Dankie Meneer.
Where can you buy the replacement copper cable??
The internal black one
how to reaire jack sir