REPAIR GUIDE - TurboExpress: A/C Adapter Fix

[akaviolence]

Maybe someone has already come up with this and I just haven't seen the post, but I thought I better share my experience so far. I had a feeling it was not the jack inside the express that was to blame, but likely the plug on the a/c adapter. I carved into the end of one to see there's not much inside to make contact with the express jack so I ordered a couple new ends from Mouser and just got done installing them. As far as I can tell it was a successful repair!
I had an express and a/c combo that would cycle on and off with the slightest cord movement, after the plug repair, constant power even with tons of cord movement.
Plug # at mouser: 171-3224-ex. Cost $1.16. One more stupid problem with our beloved toys resolved: priceless...

[BlackandBlue]

Awesome!  My Turbo Express A/C adapter does the same thing and it's driving me crazy.  Glad to see it's a quick and easy fix.  I'm going to have to order one of those ends and fix my A/C adapter.  Very good find.

[Paisa49]

Great fix, I have an AC adapter too that has the same issue.

[Red Ghost]

Good work  You should add one more image or a little diagram showing how to attach the wires properly and then this should become another Repair Guide.

[blueraven]

Agreed; you just solved the problem for my broken supply as well!

[akaviolence]

Ok, step by step and drawing for the DIY'er:

Cut off original a/c end.
Strip off a half inch of the black, pull back the wire and twist up nice in order to thread through the hole in the new plug connector.
Strip off a quarter inch of yellow plastic insulation and twist up to thread through other new plug connector hole.
Disassemble new plug by prying in half.
Feed wires through holes in correct leads as shown in drawing and apply rosin core solder.
Crimp in the tabs to hold cord in place.
Put plug halves back together.
Plug in to wall and check voltage with a DMM if you have one, red lead core and black lead shell, if you see 7 VDC you're done!
Plug in to TE and enjoy the fruits of your labor...

[Red Ghost]

Awesome! I'd suggest posting a request in the following link to make this topic into a "REPAIR GUIDE sticky" topic - http://www.pcenginefx.com/forums/index.php?topic=6517.0

[Pcenginefx]

Thanks for the repair guide akaviolence.  I have made it a sticky.