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Mark or note the edges that need to be cut to open the AirPort Express case.
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Use a dremel tool with a thin cutting bit to slowly cut around the marked edges. Cut evenly along the middle of the edges, and make several shallow passes to ensure that you don't accidentally cut into any of the components inside.
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Use a metal spudger or prying device to begin levering the case halves apart.
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Once the case halves are loose, use your hands to pry open the case.
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Trace the red, orange and black power wires to their connector on the power supply.
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Disconnect the power cables from the power supply.
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Remove the grey power inlet from the case half it is still attached to. Use a pair of pliers to rock the power inlet back and forth until it breaks free from the glue.
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Finish separating the case halves.
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The power supply is attached to the upper case half with one 5.38 mm Phillips screw.
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Use a #1 Phillips screwdriver to remove the screw and then remove the power supply.
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The printed circuit board (PCB) supplied in your kit can be soldered using any rails that you desire. However, we have determined that using the following rails provides a nice, low-profile, fit.
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Ground
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5V
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3.3V
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"Adjust"
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The following are the suggested hole locations for components, though they can be placed in any hole along the proper traces.
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.1 µF Capacitor
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1 µF Capacitor
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240 Ω Resistor
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390 Ω Resistor
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Voltage Regulator Pin 1
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Voltage Regulator Pin 2
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Voltage Regulator Pin 3
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The power inlet and outlet wires are recommended to be soldered in the following locations, though again they can be soldered to any through-hole you desire along the proper trace.
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Power Supply +
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Power Supply -
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5 V Out
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3.3 V Out
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Ground Out
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The voltage regulator has 3 pins:
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Pin 1: V in (5 V)
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Pin 2: V out (3.3 V)
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Pin 3: "Adjust"
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Use a pair of pliers to carefully bend pin 1 down 90°, pin 3 up 90° and pin 2 up as far as possible without touching pin 3.
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Use needle nose pliers to bend just the tips (approximately 2 mm) of the pins 90° up so that they are pointing the same direction as the IC face.
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Place the pins of the voltage regulator through the holes indicated in step 7. Adjust the pins if necessary.
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Solder the pins to the board on the printed side of the PCB.
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Insert the leads of the 390 Ω resistor through the holes indicated in step 7. This resistor will have an orange, grey, brown and gold band on it. The direction of the resistor does not matter.
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Solder the resistor to the PCB and clip off the excess leads.
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Insert the leads of the 240 Ω resistor through the holes indicated in step 7. This resistor will have a red, yellow, brown, and gold band on it. The direction of the resistor does not matter.
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Solder the resistor to the PCB and clip the excess leads off.
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Insert the leads of the 1 µF capacitor through the holes indicated in step 7. The capacitor will have markings on it indicating its capacitance. The direction of the capacitor does not matter.
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Solder the capacitor to the PCB and clip off the excess leads.
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Insert the leads of the .1 µF capacitor through the holes indicated in step 7. The capacitor will have markings on it indicating its capacitance. The direction of the capacitor does not matter.
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Solder the capacitor to the PCB and clip the excess leads off.
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Cut the lead off of the power supply included in the kit.
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Strip the outer sheath off the wires. You can use either wire strippers with the correct size hole, or you can use a pair of wire cutters to carefully cut just the outer sheath.
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Strip approximately 7 mm of wire, being careful not to accidentally cut the wire.
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Pre-tin the exposed wires to add rigidity to them and keep them from fraying when pushing through the PCB through-holes.
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Insert the leads of the power supply through the holes indicated in step 8. Insert the wires until the wire sheath is against the PCB.
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Solder the wires to the PCB and clip off the excess wire.
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Cut the connector off the power wires in the lower AirPort Express case half.
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Strip approximately 5 mm off each of the wires, being careful not to accidentally sever the wires.
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Twist the exposed ends of the same-colored wires together.
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Cut the included 150 mm wire into 3 equal 50 mm lengths.
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Strip approximately 5 mm of sheath off both ends of the 3 wire pieces.
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Secure a wire and pre-tin both of its ends. Repeat for the remaining two wires.
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Align the pre-tinned section of the cut wire with one of the lower case power wires. Melt the two pre-tinned sections together length-wise. Repeat for the remaining two wire sets.
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Cut the included heat shrink tubing into 3 equal length pieces.
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Slip a piece of shrink tubing over each of the exposed solder joints.
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Use the soldering iron to apply a little heat evenly around each of the shrink tubing pieces until they are secured to the wire.
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Insert and solder the wires from the AirPort board into the appropriate holes of the PCB.
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The red-wired lead goes to the 5 V out hole from step 8.
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The orange-wired lead goes to the 3.3 V out hole from step 8.
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The black-wired lead goes to the ground out hole from step 8.
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Secure the PCB to the upper case half using the original 5.38 mm #1 Phillips screw and the included washer.
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Peel the white back off the thermal pad, being careful not to accidentally peel the thermal pad off of the heat sink.
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Set the heat sink onto the voltage regulator so that their lower left corners, as oriented in the third picture, are aligned. Press the heat sink firmly onto the voltage regulator to ensure that it will stick.
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Put the case halves together. Be careful not to pinch the 3 power leads, and be sure to route the power supply cable out of the opening in such a way that it won't put tension on any of the PCB components.
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There are likely large burrs (shredded plastic bits) on the edges of your case from cutting it open. For ease of joining the case halves, it is recommended that you smooth the edges by de-burring them. A dremel tool with a sanding bit, a sanding block, or a knife will work for this process.
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Pour a small amount of the plastic beads that were included with the kit into a heat- and stick-resistant container.
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Use a heat gun to heat the plastic beads until they turn transparent.
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Give the plastic beads a few seconds to cool, then remove them and mash them together until they form one piece.
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Stretch the glob of plastic into a thin strip that will fill one of the gaps between the case halves.
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Press the plastic into the crevices and smooth it out with your finger.
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When you are satisfied with the smoothness and fill of the crevice, allow the case and plastic to cool for approx 10-15 minutes. The plastic filler will become a milky white color when it is fully solidified.
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Repeat steps 29 through 35 for all of the crevices created from cutting the case.
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Allow the case to cool for at least an hour when you have finished sealing it. This will prevent you from starting the AirPort Express while components are too hot.
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7 comentarios
First of all: thanks for creating this all-in-one repair kit.
Now my question: it looks like it is based a US power adapter (in 110V). Therefore, I was wondering if you have done the same kit for Europe (220V) since it does not appear on your EU store.
Regards,
Jeremy
Is it possible to add battery here – to make wireless airport for music listening by Apple's Airplay (Wi-fi)?
Bluetooth is awful for music with no quality at all until we get someday 5.0
I noticed that Apple's airport express is getting hot during operation, maybe this problem can be managed with getting rid of converting power supply (battery direct needed voltage).
Hi there
Firstly thanks for the excellent repair kit. Everything is great with the repair until I’ve hit the same issue as Johan, in that the ribbon cable between the two halves are all black. When you look at the PCB it helpfully says 3.3V and GND. In a leap of faith I’ve assumed (always dangerous!) that the loom is identical to Phillip’s teardown in that Apple wouldn’t go to the lengths of massive redesigns between versions and have grouped the wires as per two orange, one red, three black (using my all black connector) but there’s no joy. I haven’t released any magical blue smoke yet but am loathed to try random configurations of wires. Can anyone help please? I can post photos if necessary
John
Hi everyone. I have the same problem. Any suggestions ??
image here