Hi Everyone,
Please take a look at this other thread I've been posting.
http://www.droidforums.net/forum/te...ions/27053-droid-headphone-jack-self-fix.html
Summary:
Cause of the issue: So I was looking at teardown images and it LOOKS to me like the droid headphone jack isn't even attached to the board at all!! It kind of looks like its only attached to the back end of the phone and it just 'rests' on the board connection areas. They probably do this so it has a little more give but those pins must be lifting off the board as they get older/less flexible/bent whatever.
Take a look at
http://www.phonewreck.com/wp-content/uploads/2009/11/Droid46.jpg
The ZUNE has a ribbon. Take a look at this ZUNE hd teardown pick
http://s1.guide-images.ifixit.com/igi/NmCoGApC4PNsLqrZ.large
and here is the ipod touch
http://s1.guide-images.ifixit.com/igi/XqLrUHgSEYERiT4u.large
For the apple and m$soft products the headphone jack is physically connected, not just resting on the board.
DIY FIX (although you should take it back to the store, don't bother calling): I took a standard envelope, cut a small triangular wedge from the flap, folded it in half, wedged it in between the outside of the jack and the phone (at the 'bottom' of the phone, the side opposite the screen), and then trimmed the edge with a bit left so I can still get it out if needed. This did the trick. This keeps the headphone unit, which is basically free floating, up against the contacts on the board.