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How to fix a broken cable on Marshall Major II Bluetooth

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  1. How to fix a broken cable on Marshall Major II Bluetooth, Unclip earcups: stap 1, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Unclip earcups: stap 1, afbeelding 2 van 2
    • Earcups can be easily unclipped from the hanger piece holding them

  2. How to fix a broken cable on Marshall Major II Bluetooth, Remove earcup covers: stap 2, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Remove earcup covers: stap 2, afbeelding 2 van 2
    • On both sides:

    • Remove foam protection

    • Turn the plastic cover 45° to remove it

  3. How to fix a broken cable on Marshall Major II Bluetooth, Remove right earcup label: stap 3, afbeelding 1 van 1
    • Unglue right earcup label

  4. How to fix a broken cable on Marshall Major II Bluetooth, Unscrew earcup covers: stap 4, afbeelding 1 van 1
    • Unscrew covers with a Philips #0 head

    • 4 screws by earcups

  5. How to fix a broken cable on Marshall Major II Bluetooth, Left earcup casing contents: stap 5, afbeelding 1 van 1
    • Left earcup casing contains:

    • Lithium battery

    • Button and button connection PCB

    • Left speaker

  6. How to fix a broken cable on Marshall Major II Bluetooth, Right earcup casing contents: stap 6, afbeelding 1 van 1
    • Right earcup casing contains:

    • System on Module with all logic and amplification

    • Jack connection

    • Microphone

    • Right speaker

  7. How to fix a broken cable on Marshall Major II Bluetooth, Cable between left and right: stap 7, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Cable between left and right: stap 7, afbeelding 2 van 2
    • Cable between left and right is a 5-pairs cable with insulating paint.

    • Cable pinout is: Play/Pause, Next, Back, Volume +, Volume -, GND, Bat+, NTC, Left speaker +, Left speaker -

  8. How to fix a broken cable on Marshall Major II Bluetooth, Desoldering battery V+: stap 8, afbeelding 1 van 1
    • Desolder and insulate the V+ battery red cable

    • This way you will keep things safe from false contacts and destruction

  9. How to fix a broken cable on Marshall Major II Bluetooth, Testing speaker impedance: stap 9, afbeelding 1 van 1
    • To test if the speakers are working, use a multimeter

    • Resistance between speaker + and - plots (red and black cables) should be around 62 ohms

  10. How to fix a broken cable on Marshall Major II Bluetooth, Ease access to the button board: stap 10, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Ease access to the button board: stap 10, afbeelding 2 van 2
    • If you need to remove the button board from its casing, there is a small clips allowing to free the plastic piece holding it in place

  11. How to fix a broken cable on Marshall Major II Bluetooth, Test the cable: stap 11, afbeelding 1 van 1
    • With the multimeter, test the continuity for each line between left and right boards

  12. How to fix a broken cable on Marshall Major II Bluetooth, Free some cable length: stap 12, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Free some cable length: stap 12, afbeelding 2 van 2
    • In my case, the cable is damaged close to the left side

    • In order to free more of the cable to be able to work on it, remove the glue holding it on the earcup casing

    • Remove the gold crimp piece with a wire cutter

  13. How to fix a broken cable on Marshall Major II Bluetooth, Free more cable length: stap 13, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Free more cable length: stap 13, afbeelding 2 van 2
    • Need even more cable length? Attack on the headband side

    • First, remove the copper clip holding the fabric and foam

    • Scrap the glue to push fabric and foam away

    • There is a plastic piece holding the cable inside the headband, the only solution I found to get me some more cable length was breaking a part of this plastic piece

  14. How to fix a broken cable on Marshall Major II Bluetooth, Strip the wire: stap 14, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Strip the wire: stap 14, afbeelding 2 van 2
    • Strip the wire around the damaged part of the cable

  15. How to fix a broken cable on Marshall Major II Bluetooth, Scratch insulating paint: stap 15, afbeelding 1 van 1
    • Separate the damaged strand from the others

    • Gently scratch the insulating paint from the strand with a scalpel until you see some shiny, fresh copper color

  16. How to fix a broken cable on Marshall Major II Bluetooth, Repair the damaged strand: stap 16, afbeelding 1 van 2 How to fix a broken cable on Marshall Major II Bluetooth, Repair the damaged strand: stap 16, afbeelding 2 van 2
    • Tin the strand

    • If need be, add an additional tinned bit of thin cable to help you reconstruct the strand

    • Test the cable with a multimeter until you manage to reconstruct continuity

  17. How to fix a broken cable on Marshall Major II Bluetooth, Insulate strands: stap 17, afbeelding 1 van 1
    • Using your favorite option, electrician tape, hot glue or else, make sure the repaired strands never touch each other

    • Reconstruct the cable as solid as you can, using tape or glue

  18. How to fix a broken cable on Marshall Major II Bluetooth, Resolder the battery: stap 18, afbeelding 1 van 1
    • Don’t forget to resolder the plus side of the battery, without making any contact with anything else

  19. How to fix a broken cable on Marshall Major II Bluetooth, Secure cable: stap 19, afbeelding 1 van 3 How to fix a broken cable on Marshall Major II Bluetooth, Secure cable: stap 19, afbeelding 2 van 3 How to fix a broken cable on Marshall Major II Bluetooth, Secure cable: stap 19, afbeelding 3 van 3
    • Add some tape or glue to secure the cable:

    • In the headband, where we broke a bit of plastic

    • In the earcup, where we removed glue and crimp around the cable

  20. How to fix a broken cable on Marshall Major II Bluetooth, Bonus: scraping the headband skai: stap 20, afbeelding 1 van 1
    • If the skai finish on top of the headband is ragged, you can scrap it away, for instance with a stainless steel sponge

Conclusie

To reassemble your device, follow the unmounting instructions in reverse order.

If you cannot patch your cable, use one of the button commands strands to replace your damaged strand. You would just sacrifice a minor feature for the greater good.

This fix is quite fragile, so next time I have to repair this headset, I will try completely changing the cable for a sturdier 4-pairs Cat-5 cable - I will just disconnect Previous and Next to spare one pair.

Eve Redero

Lid sinds: 02/28/22

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