Enhancing Hakko FX-888D: Upgrading the Troublesome Connector & Adding Orientation Indicator

In this video, I'll walk you through the repair process I undertook for my Hakko FX-888D soldering iron, which had an issue with its 6-pin DIN connector. I genuinely appreciate this soldering iron for its rapid heating, temperature stability, and overall solid build quality. Nevertheless, the 6-pin DIN connector presented a notable design flaw that demanded attention.

The primary problem revolved around the fragility of the connector's plastic tabs, which tended to break easily due to frequent insertion and removal. This became particularly problematic because I often transport my soldering iron, increasing the risk of damaging the connector during these handling maneuvers.

To ensure a lasting solution, I opted for a comprehensive repair. I procured a new 6-pin DIN connector with a sturdy metal shell, offering enhanced durability and a more substantial surface area for stability. During the replacement process, I also widened the holes for the bolts cautiously, employing a counterclockwise drill to avoid overzealous metal removal.

To eliminate any potential confusion with wire connections, I diligently documented the wire colors and their corresponding pins. Additionally, I transferred a 1 Megaohm resistor from the old connector to the new one, ensuring continuity.

Soldering the wires to the new connector posed an interesting challenge, given the absence of a conventional soldering iron. To work around this limitation, I employed a unique technique - I plugged in the soldering iron, allowed it to reach the desired temperature, and then promptly unplugged it to mitigate electrical hazards. This process was repeated as needed to achieve secure soldering connections.

Finally, I reassembled the soldering iron, introducing a visual indicator to assist in orienting the connector correctly. I also showcased the soldering iron's rapid heating capabilities. This repair not only rectified the problematic 6-pin DIN connector but also bolstered the overall robustness and reliability of the soldering iron.

I trust this video will prove valuable if you encounter a similar issue with your soldering iron. If you find this content helpful, please consider subscribing to my channel for more informative content!

All music from royalty-free from YouTube Audio Library
- Believe (Instrumental) - NEFFEX
- Guess I'll Never Know - TrackTribe

[quademasters]

Just got mine. I'll wait for it to break before I do this too. Thanks.

[angelo]

Does anyone know if the newer varient of this station addressed and fixed this issue? The fx888dx from what I can see it looks the same?

[flint]

Informative video. My Hakko just became intermittent at the din, even though all looks fine. Will use your fix.

[goodun]

A Dremel tool probably would have been easier for elongating the notches where you need to mount the connector to the plastic front panel. And man, them screws are rather a bit larger than they need to or 3 mm hardware would be more appropriate, and you wouldn't have needed to drill out the DIN plugs' mounting holes.

[dovetomarc]

Love the video. The music a huge annoying distraction with all due respect.

[Crappy.Consumer.Reports]

This music was not a good choice and not only because it’s too loud.

[straightkey]

Could be a fake judging by the label on the bottom.