By James Kim
(December 1, 2005)

The Apple iPod Mini, with its seamless and soft metallic body and its charming personality, is now a classic. Now that it's been replaced by the Nano, the Mini can retire to the secondary online market, where prices are still pretty high; a 6GB Mini still goes for more than $200 online. But all iPod batteries die--some soon, some later--so it's handy to know what to do when your iPod Mini just can't hold as much juice as it used to, especially since the iPod and all of its siblings do not have batteries designed to be removed (as seen on the microdrive-based iRiver H10). Do you sell it on eBay? Do you toss it in the corner and get a new player? Or do you revive a now classic MP3 player? In this Weekend Project, I'll detail your dead battery options and explain step by step how to replace your iPod Mini's failing battery.

Replace your iPod Mini battery

If you've had your iPod Mini for less than a year, the standard Apple warranty will cover your ailing battery. If you have less than a 50 percent charge on your battery in the second year, Apple will replace that battery as well.

Although you can get your dying or dead batteries replaced by Apple for $59 (down from a hefty $99 plus $6.95 for shipping), it's easier, more fulfilling, more adventurous, and most importantly, cheaper to do it yourself with a third-party battery kit. Those who have a first-gen iPod Mini with its paltry 12 hours of life can upgrade to a current battery that lasts up to 20 hours. Battery kits for the iPod Mini are available from a number of sources, including:

• Laptops for Less ($29)
• PDASmart.com ($40)
• Batteryship.com ($21.95)
• Or buy the battery separately and pick up a small flat-head and Phillips-head screwdriver from your local hardware store

Battery replacement kits usually include a lithium-ion battery (7.2 or 3.7 volts), a multiuse tool, and basic diagram style instructions. If your kit doesn't come with a tool, use a small and thin flat-head and Phillips-head screwdriver.

Now, a word of warning before you purchase a battery: It's not too difficult to replace your iPod's battery, but those who wouldn't be able to install RAM in a computer should probably stay away. Unless you have decent surgical abilities, you'll probably end up scratching or even denting the Mini's anodized aluminum exterior--the edges around the top and bottom, to be exact. It's actually a bit easier to replace a regular iPod's battery (first through fourth generations, though the fifth-gen iPod looks trickier). We didn't care too much about our blemishes; our first-gen iPod Mini was tired and old anyway. But be aware that you'll definitely void your Apple warranty by opening up the case; again, our iPod's warranty expired a while ago.

Replace your iPod Mini battery

Once you have your battery, you're ready to assume the role of Dr. Frankenstein. Before opening the case, make sure the iPod Mini is turned off and the hold button is activated. Insert a tiny flat-head screwdriver between the white plastic top face and the metal body. Once you have it in there, gently pry upward. It may take a little force; the cover is attached by an adhesive.

Once the cover is off, unscrew two tiny screws on either side of the Mini's top. Keep these screws somewhere safe.

Next, go to the bottom of the Mini and remove the white cover the same way you did the top. Once this is removed, you'll notice a metal clip. Remove this by placing the tip of a screwdriver in each of the four corners, prying it loose. Again, you may need to use a bit of force, though the clip typically snaps out easily.

Before sliding out the motherboard, you'll need to disconnect the connector at the bottom of the Mini. Simply use the tool to pull the connector out of its socket.

Push the motherboard from the bottom and out through the top. You should see the LCD first. Now you have access to the battery, which is most likely colored blue and is on the opposite side from the LCD.

Replace your iPod Mini battery

Since you're taking apart your iPod Mini, you might as well know what's inside. The front of the player includes the 1.7-inch monochrome LCD and, below that, 32MB of RAM (for buffering) and the main 80MHz dual ARM 7TDMI processors (PortalPlayer PP5020). The Click Wheel and the controller, still attached to the metal body, plug into a port on the bottom.

The backside is where you'll be installing the new battery. Notice the existing OEM battery is blue, just like the replacement. The battery--this particular one lasted eight hours per charge when new--plugs into a socket above. Below the battery, you'll notice the hard drive, which is actually a 1-inch microdrive (in our case, a 4GB Hitachi drive) that can be pulled out and used in digital cameras (with CompactFlash Type II slots) or other devices. The drive will be secured by some cheap-looking tape, though we've removed ours. The top of the Mini, which includes the headphone jack, might come off during disassembly. The tiny circuit board plugs right into the motherboard.

Replace your iPod Mini battery

Gently lift the blue battery and lay it to the side. You must disconnect it from the motherboard before you can take it out completely. Set the new one in and attach the connector. If the battery cable is jutting out, gently tuck it inside the space between the battery and the connector--you'll want it to be as streamlined as possible when sliding the motherboard back into the body. Don't forget to properly dispose of the dead battery.

Replace your iPod Mini battery

Hold the motherboard, making sure the battery is in place, and slide it, bottom first, through the top of the Mini body. Be sure that the motherboard slides in under the internal metal grooves. Tuck in the battery cable if necessary. Once it's seated tightly, put back the two tiny screws up top, then reconnect the cable on the bottom end. Then push the metal clip so that each corner fits in its respective groove. It should snap in. Finally, snap in the white bottom and top covers--the existing adhesive should stick well enough, but if you want to reinforce it, use a tiny bit of strong glue.

Replace your iPod Mini battery

While I would personally test to see if the iPod's replacement battery worked before the final reassembly steps, it's important that all the components are tightly fitted just as they were before you started. Once you verify that the battery works, you should drain the battery, then recharge it for three hours before your first use.