First things first, the Zune is actually screwed together, unlike the iPod (or at least the older generation iPods I’ve ripped apart.) Do not attempt to simply pry the case apart unless you really don’t intend to put it back together again.
The little piece of black plastic surrounding the docking port pops out to reveal two very tiny philips type screw heads. Remove them and then pry the case apart, lifting it apart from the butt first. Watch out for the head phone plug - it extends through the shell and will catch on the case if you just pull it apart.
Be aware that the battery is not mounted to anything and will simply fall out. The battery rests at the top of the Zune, just under the hold switch. The flat ribbon cable runs down the body, over the hard drive casing, to a small plug at the bottom of the mainboard. The weight of the battery will crease the ribbon cable and pull the plug out if you are not working on a flat surface and allow the battery to tumble out.
On my Zune, the hold switch is malfunctioning and the audio jack fluxes between mono and out. If I can find someplace to buy a replacement audio jack, I am going to attempt to replace it. At this point, I have wasted 90 minutes trying to find any 3.5mm stereo 6-pin jack. So far, nothing that looks remotely the same or would fit in the space provided. I think I am still going to try removing the hold switch… hopefully that won’t do anything worse than the permenant hold that I already have going on.
to be continued…
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