How to Disassemble an iPod Touch
Repairing your defective iPod Touch in case of a broken digitizer (touch screen), headphone jack, connector dock or battery is far more cost-effective than purchasing a brand new part. If your warranty is expired and your device is non-operational, it is worth the time and effort to attempt to repair it yourself. Whichever part needs servicing, you will need to disassemble the iPod Touch completely. These steps will provide a guideline for doing so.
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Instructions
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Acquire an iPod/iPhone repair kit. These are special tools designed specifically to open an iPod safely. They can be found at various online vendors, such as WeLoveMacs and PDASmart. Alternately, you can use a medium guitar pick and a T5 Torx and T6 Torx wrench.
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Insert the nylon case opening tool into the corner of the iPod casing in the seam between the silver portion and the front. Apply pressure, as if you were stabbing a potato. You may find this step easier if you use two guitar picks at two different spots. The corner is typically the easiest place to penetrate the seam.
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Move the tool or guitar pick along the seam to loosen the clips attaching the two parts of the iPod Touch case. Once you have gone all the way around the case, the case should come apart.
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Carefully peel back all the black electrical tape on the parts. Do not remove it completely; rather, peel it back until you've exposed all the screws in the iPod.
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Remove all visible screws in the iPod Touch. You can use the T5 or T6 Torx wrench for this.
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Gently pry out the battery. Be careful--the battery is somewhat malleable and is glued in place. Remove it gently, moving along the edges and then moving towards the center to prevent deforming the battery. Once the battery is free, set it aside without removing the connecting wire.
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Using the nylon case opening tool, lift the plugs attaching the ribbons to the logic board. There are two of these, one on each end--the black one ends on the bottom end and the brown one ends at the top end.
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Pry the metal plate off near the bottom. This will expose three black components attached to another metal piece. Pry this metal piece off. You now have access to all the inside parts of your iPod.
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Tips & Warnings
Reassemble your iPod Touch by replacing the items in reverse order.
Never force a piece until it breaks. Be sure that you have removed all screws if you meet undue resistance. Opening your iPod will void your warranty.
