Chosen Solution
I’ve got an iPod classic 80gb that I purchased new in 2008. Somewhere around 2010 the headphone jack failed in it due to my own stupidity with my car’s audio system. So i ordered a cheap replacement from China. The problem I have, is that any adjustment below half volume makes zero difference at all. I have verified that audio through the dock connector is identical to my one year newer 120gb model, and with the dock remote I am able to control the volume on them the same. Is this an issue with the cheap Chinese headphone jack? Or does the device need a new main board? I’m pretty sure it needs a board. I have tried a known good headphone jack that is showing that performs the same. I plan to soon try this headphone jack on a different device and will report back. Trying to find a logic board for this thing that isn’t worth its weight in gold is proving difficult.
Do you have the logic board number? I have found a supplier that has them you will just need to logic board number. Update (05/14/2020) The new logic board is 101 dollars. The good thing is you would know it’s a brand new part.