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How to replace your Sansa Clip Battery

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How to replace your Sansa Clip Battery  Empty How to replace your Sansa Clip Battery

Post  Lisi on Tue Aug 10, 2010 7:14 pm

One of my Sandisk Sansa Clip batteries didn't hold a charge for longer than a few minutes anymore. I ordered a $5 iPod Shuffle battery from Dealextreme. This is the closest to the Clip's battery measurements I could find. Of course it's very easy getting spare parts for iPods in retail, but near impossible for any other brand player.

After 28 days the battery (including nice prying tools) arrived from Hong Kong, and I got to work replacing the Clip's battery. It's easiest starting by the power switch when opening the Clip up. Make sure not to break anything.
How to replace your Sansa Clip Battery  P5170339mod
How to replace your Sansa Clip Battery  P5170340mod
The Shuffle battery is smaller but a bit thicker than the original battery of the Clip.
How to replace your Sansa Clip Battery  P5170341mod
The Clip battery has a circuit board with three connectors, plus, minus, and "N". The Shuffle battery has four connectors, and wouldn't work with the (overcharge/thermal?) safety circuit the Clip has built in.
How to replace your Sansa Clip Battery  P5170342mod
At first I made a mistake, I wanted to use the Shuffle battery as-is, with its original circuit board (which won't work properly with the Clip). I de-soldered the three cables from the Clip's circuit board, instead of doing the right thing and removing the whole board from the battery (which is way less work than desoldering the three poles).
How to replace your Sansa Clip Battery  P5170347mod
When I realized my mistake I removed the PCB from the Shuffle battery, and cut the two poles that lead into the battery diagonally, to fit the Clip's battery PCB.
How to replace your Sansa Clip Battery  P5170348mod
The Clip's PCB soldered onto the Shuffle battery. Make sure to keep the polarities right. (If I would have thought the procedure through, there would still be the cables attached to the PCB, and I would have had much less work.)
How to replace your Sansa Clip Battery  P5170349mod
The cables soldered onto the PCB again. Note to self: think first, solder later.
How to replace your Sansa Clip Battery  P5170350mod
Electrical tape to prevent shorts.
How to replace your Sansa Clip Battery  P5170351mod
Needs more tape.
How to replace your Sansa Clip Battery  P5170352mod
Placing the battery on the Clip's main board, making sure none of the flimsy cables break.
How to replace your Sansa Clip Battery  P5170353mod
Putting the Clip together again. Try not to forget the volume rocker and power switch. The Shuffle battery is slightly thicker, but it still fits inside the housing and it doesn't wiggle around. As you see, the DX battery got about 40% charge, just the amount that is recommended for storage by BatteryUniversity.
How to replace your Sansa Clip Battery  P5170355mod
anythingbutipod

Lisi

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