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I have a bad connection with the 3.5 jack on my ipod shuffle 4th G.
Tested with several headphones and speakers, I need to hold the jack to get sound.
Can I re-establish contact without dismantling the device?
I've already tried blowing out the dust and removing it with a needle.
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About all that's left to do would be to maybe try flushing it out with 90% or higher concentration isopropyl (rubbing) alcohol then blow it clean with a can of compressed air. If that fails then yeah, you're down to opening up the Shuffle and removing the logic board.
iPod Shuffle 4th Generation Logic Board Assembly Replacement - iFixit Repair Guide
Once the board is out, you might be able to see if there's something wrong with it. Unfortunately, I wasn't able to find any information on how to go about replacing the headphone jack so I'm afraid that's something you'd have to figure out for yourself. The part itself is readily available online but I can't tell just from pictures how it's attached to the logic board. You may have to solder it, or perhaps not. Here's an example of where you can buy the part; there are many more online.
If you decide to tackle the replacement, be sure to take lots of pictures, then you can use them to author your own guide and help out the iFixit community, who will appreciate it.
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