Step 1 — Rear Panel
Before opening your iPod, ensure that the hold switch is in the locked position.
The rear panel is secured to the front case by eleven clips permanently attached to the rear panel. These clips lock onto small tabs machined into the front case.
To free the tabs, they must be pushed toward the center of the iPod. Note the location of all tabs on the rear panel. When using an iPod opening tool to free the rear panel, be sure to work the tool at the location of these clips.
Opening the iPod can be challenging. Don't get discouraged if it takes you a few tries before the iPod is opened.
Insert the large iPod opening tool into the seam between the front case and rear panel of the iPod, below the dock connector. Run the tool back and forth to create an opening. The tool's edge should point toward the rear panel to prevent any accidental scratching of the aluminum front case.
Insert a small iPod opening tool into the seam on the Hold button side of the iPod, with the edge of the tool pointing toward the rear panel.
The large iPod opening tool is no longer needed to gain access to the left side of the iPod.
Gently enlarge the existing gap by pressing/wiggling the small iPod opening tool into the gap near each of the the two tabs attached to the rear case, pushing the clips toward the center of the iPod until both have been freed.
Repeat the same procedure listed in the previous step to free the five clips along the headphone jack side of the iPod.
After ensuring all tabs are free, separate the two halves of the iPod.
The rear panel is now free from the iPod.
Step 8 — Battery & Logic Board
Remove any kapton tape over the screws, if necessary.
Remove the following 3 screws:
Two 3 mm Phillips screws near the dock connector.
One 4 mm Phillips screw along the edge of the logic board.
Peel up the ground strap connecting the battery to the logic board.
Insert the flat end of a spudger between the battery and the headphone jack side of the front case to pry the battery up off the adhesive securing it to the front case.
Rotate the battery out of the iPod and lay it next to the iPod. The battery is still soldered to the logic board by three wires, so don't remove it entirely.
Gently lift up on the dock connector end of the logic board to ensure the logic board is free.
Grasp the end of the logic board near the battery connector with one hand, and hold onto the rest of the iPod with your other hand.
Make sure the logic board is lifted slightly above the white plastic notch on the battery side of the board. This notch prevents the board from sliding out in the next step.
Slide the logic board out of its holding brackets on the rear of the display.
The logic board is still connected to the iPod by two ribbon cables.
Disconnecting the following two ribbon cables may be challenging. To prevent straining the cables or connectors, you can only separate the two halves of the iPod about 1/2 inch during the process.
Use a spudger to flip up the black plastic tab holding the orange display ribbon in place. The black tab will rotate up 90 degrees, releasing the ribbon cable.
Use a spudger to slide the display ribbon out of its connector.
Use a spudger to flip up the black plastic tab holding the orange click wheel ribbon in place. The black tab will rotate up 90 degrees, releasing the ribbon cable.
Use a spudger to slide the click wheel ribbon out of its connector.
The logic board and battery are now free from the iPod.
Step 18 — Display
Use a spudger to carefully pry up the adhesive holding down the edge of the display.
Be careful not to slide the spudger in too far to prevent scratching the display.
Gently lift up on one corner of the display to separate the adhesive holding the display in place.
Lift up on the other corner of the display in the same manner.
Lift the display up and out of the iPod.
The display is now free from the iPod.
Step 22 — Click Wheel Cover
Lift up on the click wheel cover and carefully thread the orange click wheel ribbon through the slot in the click wheel cover.
Lift the click wheel cover out of the iPod.
To reassemble your device, follow these instructions in reverse order.