Many forum members have been reporting that their iPod mini is creating audio distortion when used. One such member claims to have discovered a major ‘design flaw’ in the iPod mini, which results in sound distortion when placing pressure anywhere on its surface or headphone port. The source of the noise may be a weak connection between the headphone port and the main circuit board.
“My iPod mini after two weeks of gentle use started to make horrible static noises; sometimes sound will disappear completely. Then the sound will return to normal, but any pressure as small as thumb pressure anywhere on iPod mini will make sounds to come back. Resetting iPod did not help. Guided by the detailed ‘iPod mini Autopsy’ posted here on iPodLounge, I disassembled by iPod rather easily. To check the reason of these noises, I started to play the iPod and disconnected the wheel, then the hard drive, but iPod was still playing (out of 25 min flash memory) and still making noises. Eventually, I narrowed the problem to a small little part that contains headphone and remote jack and metallic part in the shape of the white plastic top.”
“This small part attaches to main iPod board ONLY via small black connector that sits on on the main board. WHAT AN OVERSIGHT on Apple