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.
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.”