DIN Plug replacement 101
Tools Needed:
Helping Hands Hobby Tool holder, you know, the things with the magnifying glass and alligator clips.
Soldering Iron and Solder (.022 Diameter Recommended)
Hot Glue Stick and Hot Glue Gun.
Electrical Tape
Wire Cutters and Strippers
Needlenose pliers
Voltage Meter
Rubber Cement or some flexible glue
Step by Step Replacement of how I do it.
1: Cut off old Plug
2: take apart DIN plug and place the outer plastic part of the plug over the cable with large end facing cut off plug
3: Strip 5/8" off the cable exposing the internal wiring
4: pull back the metal shielding and tape it to the cable to keep it out of the way
5: Strip only about a 1/32" off of each wire.
6: Using the soldering iron and solder, Solder a little bit of solder into each of the 6 pins (be careful that no lead touches a neighboring pin)
7: Start Soldering the Color Coded wires to there Corrisponding Pins. on the side that that you are soldering the pins go clockwise from the space.
(pin1=Green) (pin2=orange) (pin3=Brown) (pin 4=red) (pin5=yellow) (pin6=black)
8: Test each pin with a voltage meter to make sure that no pins have contact with a neighboring pin, and also take apart the Control Pod carefully and test with a voltage meter from the pins on the plug to the connectors on the opposite side of the plug that is inside the pod to make sure you have a good connection all the way up.
9: put the Metal portion of the plug together and wrap some tape around it to hold it in place and insulate from heat.
10: Fill the metal section and wiring with Hot Glue to the top of the metal and let set for a few minutes.
11: untape the Metal Shielding and evenly spread it around the metal housing
12: put one section of the inner plastic plug casing in place matching it with the grooved edge to the side of the plug with the bump, then place a little hot glue inside of that piece to hold the cable, then put hot glue in the other side of the plastic inner shielding and put that on as well.
13: use Rubber Cememnt or Flexable glue and place a good ammount all around the cable up to about an inch away from the inner plastic plug and then slide the outer portion of the plug over it, lining up the bump on the plug to the groove on the inner plug (do not slide it all the way down "flush" slide it till it is about 3/32" away from the end of the plug) that way it will make better contact and hold in the plug better.
with all these steps followed properly you should now have a fully functional control pod again, Congratulations!!!