From: Wayne Downer
Date: December 28, 2003 11:41:08 PM PST
To: Ward Cunningham
Subject: iBook display problem

You're definitely not alone.  Below is the write-up that appeared on MacIntouch today, followed by several postings by Peter Hilleard, who has clearly diagnosed and documented how to repair the problem.  The Apple iBook/iBook (Dual USB)/Display discussion board is loaded with people with the same problem.  I don't know if it will get you any leverage, but I'd talk to the "Apple Geniuses" at the Washington square store and reference the documentation of the problem on their own discussion boards...  and if that doesn't work, you can either keep an eye on things to see if anyone else gets Apple to do the right thing, or we can take a shot a implementing the repair...

Later
Wayne


FROM MACINTOSH:

David Shanahan offered some important tips for avoiding trouble with iBooks:

I recently had the video die on my 800 MHz G3 iBook for the first time when it was almost out of warranty. It was fixed, though apparently because of the high demand for iBook logic boards it took three weeks to get it back. So far it's working fine but based on others' experience this is unlikely to last.

I started reading the Apple support forums on the subject of video failures in iBooks while I was waiting for mine to be repaired. It seems there are two basic flaws in the white (Dual USB) iBooks (both 12" and 14" models) which Apple seem to be studiously ignoring despite complaints about them being widespread for over a year now:

1. The hinge design is faulty. Backlight, video and power cables pass through the hinge from the logic board to the screen and the holes are too small for the cable assemblies resulting in stress and friction on the cables each time the screen is opened or closed. Eventually one or more of the cables either break or the insulation wears through resulting in a short and the backlight/video fails. This is often accompanied by fuzzy lines on the screen or users finding that the screen fails when tilted at certain angles and works at others. If your video works fine when you plug the iBook into an external monitor then this is most likely your problem. There are links in the Apple support forums to a site describing in detail how to disassemble your iBook and replace such broken cables, though you'd want to be pretty confident to try this as it will of couse void any warrenty you have left.

2. The video chip on the motherboard comes loose when its solder gives way leading to video failures, usually with no warning. This may be triggered by flexing of the case putting strain on the chip until it eventually comes loose (some have suggested never picking up your iBook by the left-hand side alone as this is where the video chip is). If after a video failure you plug in an external monitor and it doesn't work this is most likely your problem and you need a new logic board. Some people have tried pressing down hard on the left-hand side of the case just below the option key to the left of the track pad and managed to get video back temporarily (apparently this reseats the video chip). Others have reported some success sticking rubber bands/thin foam insulation on the underside of the shielding over the video chip to protect it from flexing/pressure from the case. Seems like the case really needs to be reinforced to stop it flexing like this and/or the location and soldering of the video chip changed.

These problems appear to be common with every model of white iBook from the original 500 MHz up to at least the 900 MHz G3s. The new G4 iBooks may have the same problem(s) but they're so new it's probably too soon to tell for sure (the hinge design has apparently not changed). [...]

P.S. I'd advise readers to avoid buying 2nd hand white iBooks - many people seem to be selling theirs after the 2nd/3rd/4th logic board replacement and buying something else (not always another Apple product of couse, which has got to hurt Apple if they continue to ignore these problems).



FROM APPLE DISCUSSION BOARDS:

RE: 90 degrees and black out!!!!
( msg # 11. : Posted Oct 14, 03 11:30 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
I like many others have had this same problem with the backlight going out at various angles. I have had to close lid to put it to sleep then reopen to get backlight to come on again

I have found that the problem is a break in the display backlight power and control cable where it passes through the hinge. The flexing of the wires when the lid is opened and closed fatigues and cracks one or more of the wires.  At some angles it makes contact and works and when you open it too wide it breaks contact. Typically the wire breaks contact when it is stretched when the lid goes past say 45¡  - but it varies from case to case and can change with time as the wire insulation stretches leaving a bigger gap between the broken ends of the conductors.

Four months ago I believed this was the most likely cause and today I proved it.

I have just completed repairing mine and it now works fine.

The broken wire was the black one in the backlight control cable going through the right hand side hinge. The black carries 12.5volts for the backlight.  My tests confirmed the black wire was broken where it goes through the hinge. (the other wires are still intact at this time).

As a zero cost repair -  I cut the wire near each end and soldered in a new segment of  wire to bypass the broken wire.

The wire I used is very flexible and durable earphone cable (which should better resist fatigue / work hardening failure).
I also enlarged the diameter of the semi-circular hole in the plastic hinge shroud - to avoid the stress localisation on the wires through the hinge - which is a serious design fault in the iBook.

This is a tricky repair but it beats paying the high cost of having Apple repair it (mine is out of warranty).  It would also be possible to purchase a new backlight control cable assembly - other posters have purchased one from Smalldog for about US$50.

There are pictorial guides available on the net showing how to dismantle such as http://norum.homeunix.net/~carl/mods/ and http://

homepage.mac.com/itiburon/cybergreg/iBook500HD.html

http://www.cj7jeep.com/ibook_disaster/index_2.html

http://rabu.homeunix.net/~stan/ibook/ibook.html (get the Apple manual ibk01.pdf - Stan has a link near the top of his page. This manual is very good in helping work out where all the screws came from and go back)

Good luck all


RE: 90 degrees and black out!!!!
( msg # 12. : Posted Oct 17, 03 10:38 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
Don't be mislead by the supposed reed switch problem. This is a much bigger issue.

The two wires for the reed switch (which is in the lid) pass through the hinge on the right hand side.  They are the green and yellow wires (Green is 0V: sleep switch return and Yellow is 3V sleep switch power).

These reed switch wires are just as vulnerable to failure through fatigue as the black backlight cable which failed in my iBook.  Any of these 5 wires passing through the right hand side hinge can fail and affect sleep and backlight. The symptoms depend on which wire and how many break.

Similarly, the Low Voltage Data Signal cable passing through the left hand side hinge can break and cause other problems with the display - of the type reported by others in this forum.  (flashing / lines / garbage display etc.)

Many assume the actual components such as the backlight, the high voltage inverter board or the reed switch, motherboard etc. , have failed (and Apple repair often state they replaced these components). However, I believe in nearly all cases it is not the actual component that has failed - but rather the wires leading to the component through the hinge.

The fault is in the design of the hinge which is destroying these wires and hence causing a broad range of display problems. As a professional engineer, I design and build instrumentation systems where wires travel across hinged doors on enclosures. The way the hinge on the iBook is designed and assembled causes so much twisting and tension on the wires in a very localised and cramped area that the copper cores work harden and fracture with surprisingly few opening and closings of the lid.  (in as little as 3 months of regular use).

Compounding the poor design is the inappropriate use of a standard 7 strand cable through the hinge area. I have tested the actual wire used and it is highly susceptible to strain hardening failure. They need to use higher strand numbers, which provides a more supple cable less affected by strain hardening. And they need to open up the clearances in the hinge to allow the cables to flex over a larger radius.

Apple is wrongly attributing the failures to various different components which is distracting attention away from the prime cause and allowing them to avoid a recall.

Apple's workshop manual specifies for an apparent failed display backlight - replacing the whole display, and if this doesn't work then replacing the motherboard. This is ridiculous for one broken wire! It costs them and ultimately us (in higher purchase and Applecare costs) when they unnecessarily replace good components - and they don't find the real cause of the problem.

I have provided feedback advice to Apple on this issue and asked them for an email response. They have not replied.  People on these forums with these various display problems need to realize what is happening and put pressure on Apple to come clean and acknowledge their responsibility with this display hinge design flaw.


RE: 90 degrees and black out!!!!
( msg # 15. : Posted Oct 19, 03 9:44 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
Hi Shawn, Jason and Martin,

We all seem to be on the same wavelength - this is encouraging.

Reading through this forum it is amazing how much ill-will this is causing towards Apple and this hurts me, as I have been an Apple fan since 1986 - Mac plus. BTW Shawn I looked back at info I had found around April this year and saw your posts on the 30¡ thread. Congratulations on sticking with this issue for so long.  Jason - great to see you did the repair too! - its a good feeling when we can fix a problem that seems to be eluding Apple.

BTW I sent an email to rhythmic on 15th Oct but no reply yet.

I was so angry and frustrated with this fault and Apple's attitude but I am now glad I persisted and fixed it for now (and so is my daughter - who had been using it at school and at home with great success, and she is back to school tomorrow with a functioning iBook.)

Martin, you're right about about preventing or postponing future problems. I am sure more of these wires will break in the next few months. I also thought about avoiding closing lid and using software sleep function and have suggested this to my daughter. Unfortunately, with school classes she can't avoid opening and closing. Examing the hinge function and the dynamics of the wires - the wider the angle of opening the more crushing and stretching - so I guess the moral is don't open any wider than necessary.

The problem with carrying out further ad hoc wire replacements (eg splicing in new segments) - is that it gets bulkier and more difficult to manage as more are done. I am just hoping I can manage the problem until our iBook is obsolete and up for replacement (it was purchased in Dec 2001).

Clearly, a better solution would be for Apple to acknlowledge the design fault, develop improved / more durable versions of the various affected cables and a new hinge cover and agree to install them for owners who report problems consistent with this design fault.

Below is the text of a "feedback form" I sent back to Apple Support via this website on about 12th Oct 03.  If you haven't done so already perhaps more of us need to send letters like this to Apple - since they don't seem to be reading or taking any real notice of these forum discussions. I think we also need to spread the word and look at other ways of getting these complaints through to Apple at a higher level. I am thinking of sending a letter to the local Australian Macworld magazine - a letter to editor, as it usually gets a response from the Aust. Apple management.

Good luck to all - let me know if you have any success or positive feedback from Apple (yes I know - wishful thinking! BUT you never know unless you try.

Text sent to Apple 12th Oct (before I proved the wire problem and fixed it myself);

"I searched for information in the support areas on my iBook display problem.

The only information I found is in the iBook discussion forum - and that forum shows hundreds of cases of the same problem indicating a chronic issue which some have nicknamed  'The Angle of Death" .

Sadly, I see no evidence that Apple is taking any notice of the issue. Many of your customers - including me - are getting very angry over this lack of response.

I have a Dual USB 600MHz iBook which I bought for my 15 year daughter for school.   If the screen is tilted back more than 45¡ the backlight goes out and she needs to close the lid to put it to sleep then reopen (to a reduced angle) to get the backlight to come back on. It is obviously impractical to use yet she has persisted with it at school. The other students, who were originally impressed with the iBook and the things she was doing with it - (she even won a regional film festival using iMovie) now can see that it is faulty. After proudly endorsing the iBook,  what is she supposed to tell puzzled onlookers now when they see her trying to work with the screen open at 45¡?

I believe it is a design flaw - with too much stress and flexure being applied in the backlight cable where it passes through the right hand side hinge. The cable insulation is scuffed and obviously deformed. I believe a cable core may have broken from fatigue and is making / breaking contact as it is stressed.  I design and build instrumentation systems with cables routed through cabinet door hinges and it is obvious to me that most if not all iBooks will fail in this area if they are opened and closed a sufficient number of repetitions. Many of the posts indicate the problem is occurring in as little as 3 to 5 months!

Also I suspect the cable may be shorting out against the chassis because a mild electric shock can be felt from the screw heads exposed on the bottom of the case - which can be felt especially when resting the computer on bare legs.

I am a long term Mac supporter (1986 Mac Plus) having bought at least 15 Macs at work and home and I am extremely disappointed that Apple is ignoring this widespread backlight problem. This is the first major problem I have had with Macs in all these years but I am now so concerned over this obvious quality / reliabilty issue that I am no longer recommending Macs (laptops at least) to friends and colleagues.

Also in terms of lost sales and market share, I advise that my wife (an Apple supporter since the late 1970's) is IT support manager at my daughter's college and this unresolved issue with the iBook display is adversely affecting the school's proposed programme of replacement of older Macs with iBooks.

The only way Apple will regain my confidence and ongoing support as a customer and Mac 'evangelist' is to acknowledge this problem and repair this design fault at Apple's cost.

Others in the forum posts have also mentioned the electric shock problem which our iBook is exhibiting - and if it is more widespread it should be subject to a recall. The electric shock is certainly very unpleaseant and I believe could be a safety issue such as affecting heart pacemakers or other medical appliances.

I have been following this backlight issue on the iBook discussion forum since June 03 when my problem first appeared. From the number of posts on this specific issue it seems to me that Apple is risking a class action (as well as alienating a large number of long term and influential customers) if they don't do something to stem the tide of anger growing over this issue.

I would appreciate it if Apple could email me a reply and a suggested remedy.

Yours sincerely
Peter Hilleard
Geotechnical Instrumentation Engineer
Rail Infrastructure Corporation
email: philleard@ozemail.com.au."


RE: 90 degrees and black out!!!!
( msg # 21.1 : Posted Nov 12, 03 4:18 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
David.

I have made posts on several threads about my problem and how I repaired it.  For example look for RE: Ibook is black when opened, only works 80 deg.  (msg # 1.: Posted Oct 14, 03 10:58 am)

I  found that the problem is a break in the display backlight power and control cable where it passes through the hinge. The flexing of the wires when the lid is opened and closed fatigues and cracks one or more of the wires.  At some angles it makes contact and works and when you open it too wide it breaks contact. Typically the wire breaks contact when it is stretched when the lid goes past say 45¡  - but it varies from case to case and can change with time as the wire insulation stretches leaving a bigger gap between the broken ends of the conductors.

In my case the broken wire was the black one in the backlight control cable going through the right hand side hinge. The black carries 12.5volts for the backlight.  My tests confirmed the black wire was broken where it goes through the hinge. (the other wires are still intact at this time).

As a low cost repair -  I cut the wire near each end and soldered in a new segment of  wire to bypass the broken wire.

The wire I used is very flexible and durable earphone cable (which should better resist fatigue / work hardening failure).
ÊI also enlarged the diameter of the semi-circular hole in the plastic hinge shroud - to avoid the stress localisation on the wires through the hinge - which is a serious design fault in the iBook.

This is a tricky repair but it beats paying the high cost of having Apple repair it (mine is out of warranty).  It would also be possible to purchase a new backlight control cable assembly - other posters have purchased one from Smalldog for about US$50.

There are pictorial guides available on the net showing how to dismantle the iBook such as
http://norum.homeunix.net/~carl/mods/

http:// homepage.mac.com/itiburon/cybergreg/iBook500HD.html

http://www.cj7jeep.com/ibook_disaster/index_2.html

http://rabu.homeunix.net/~stan/ibook/ibook.html (get the Apple manual ibk01.pdf - Stan has a link near the top of his page. This manual is very good in helping work out where all the screws came from and go back)

Your problem could also be the reed switch / inverter cable as noted by Greg Haskel Message #. 19.  This cable also can get damaged in the hinge. I posted a way to test this cable on a thread called   RE: Screen goes black when adjusted  (Oct 19, 03 8:04 am)
The reed switch which is also known as sleep switch (it looks like a small glass tube with thin metal reeds in it) which is attached by a single screw to the display frame.  If you have a multimeter you can test the function by testing for continuity between the green and yellow wires (which go through the right hand side hinge - access the wires at  the plug-in connector on the top of the motherboard near the top right of the airport card area).

First test that you have continuity between each end of each of the green and yellow wires - this will prove if either or both wires are broken in the hinge area.

You can get a contact point for the test probes on the front or the back of the reed switch. To get a contact point on the plug on motherboard you can insert thin wire (eg. length or resistor leg which will fit down next to the wires where they enter the top of the plug. it is best to disconnect the plug from the motherboard first.

If the wires are intact then test the reed switch performance. To get the switch to function, wave a magnet near the switch body and you should get a closing of the circuit (check with multimeter continuity test) if the reed switch is OK. (don't overdo it with a strong magnet as you could damage the reeds.) I would be very surprised if the reed switch itself is damaged - it is much more likely to be the cables at fault.

I would only suggest you carry out these repairs if you have the skills and equipment or know someone wh


RE: The Hilleard Fix: ...now, where's Apple
( msg # 2. : Posted Dec 24, 03 9:44 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 38
Frank,

Some of my posts have been removed by the moderator, although I don't know why as they haven't been offensive.

See http://discussions.info.apple.com/WebX?postMessage_@165.x9zcasPepWn.7@.599dfe9d

Apple has just changed the setup of the forums - so maybe something happened during the change. Other topics where I've posted still seem intact. I have put the info on how to fix into several other topics, For example see RE: 90 degrees and black out!!!! The posts are dated Oct 14, 17 and 19 and Nov 12 (spread over 2postings. If you search - In Apple Discussions with my surname Hilleard you will find the other posts.

See also RE: Ibook is black when opened, only works 80 deg. (msg # 1.: Posted Oct 14, 03 10:58 am)

My problem was a break in the display backlight power and control cable where it passes through the hinge. The flexing of the wires when the lid is opened and closed fatigues and cracks one or more of the wires. At some angles it makes contact and works and when you open it too wide it breaks contact. Typically the wire breaks contact when it is stretched when the lid goes past say 45¡ - but it varies from case to case and can change with time as the wire insulation stretches leaving a bigger gap between the broken ends of the conductors.

In my case the broken wire was the black one in the backlight control cable going through the right hand side hinge. The black carries 12.5volts for the backlight. My tests confirmed the black wire was broken where it goes through the hinge. (the other wires are still intact at this time).

As a low cost repair - I cut the wire near each end and soldered in a new segment of wire to bypass the broken wire.
The wire I used is very flexible and durable earphone cable (which should better resist fatigue / work hardening failure).
ÊI also enlarged the diameter of the semi-circular hole in the plastic hinge shroud - to avoid the stress localisation on the wires through the hinge - which is a serious design fault in the iBook.

This is a tricky repair but it beats paying the high cost of having Apple repair it (mine is out of warranty). It would also be possible to purchase a new backlight control cable assembly - other posters have purchased one from Smalldog for about US$50.

There are pictorial guides available on the net showing how to dismantle the iBook such as;
http://norum.homeunix.net/~carl/mods/
http:// homepage.mac.com/itiburon/cybergreg/iBook500HD.html
http://www.cj7jeep.com/ibook_disaster/index_2.html
http://rabu.homeunix.net/~stan/ibook/ibook.html (get the Apple manual ibk01.pdf - Stan has a link near the top of his page. This manual is very good in helping work out where all the screws came from and go back)

Screen black at any angle problem could be the reed switch / inverter cable as noted by Greg Haskel Message #. 19. This cable also can get damaged in the hinge. I posted a way to test this cable on a thread called RE: Screen goes black when adjusted (Oct 19, 03 8:04 am)
The reed switch which is also known as sleep switch (it looks like a small glass tube with thin metal reeds in it) which is attached by a single screw to the display frame. If you have a multimeter you can test the function by testing for continuity between the green and yellow wires (which go through the right hand side hinge - access the wires at the plug-in connector on the top of the motherboard near the top right of the airport card area).

First test that you have continuity between each end of each of the green and yellow wires - this will prove if either or both wires are broken in the hinge area.
You can get a contact point for the test probes on the front or the back of the reed switch. To get a contact point on the plug on motherboard you can insert thin wire (eg. length or resistor leg which will fit down next to the wires where they enter the top of the plug. it is best to disconnect the plug from the motherboard first.
If the wires are intact then test the reed switch performance. To get the switch to function, wave a magnet near the switch body and you should get a closing of the circuit (check with multimeter continuity test) if the reed switch is OK. (don't overdo it with a strong magnet as you could damage the reeds.) I would be very surprised if the reed switch itself is damaged - it is much more likely to be the cables at fault.

Suggest you only carry out these repairs if you have the skills and equipment or know someone who does.

Good luck.


RE: iBook screen blackouts
( msg # 2. : Posted Dec 24, 03 8:32 pm )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 38
This is a well known problem with the cables being damaged where they pass through the display hinge.  Thousands have posted in the Apple Discussion about this.  Search using the Forums Search tool in iBook - Dual USB - Dsiplays for my name "Hilleard" and you will find info on the problem and how to repair it (if you want to try yourself). Mine was out of warranty and I had no choice.

To all of you with logic board and display problems the following is a quote Extract from MacFixit
Wednesday, December 24 2003 @ 02:29 AM PST
iBook logic board problems?

Over the past few weeks, we've received a few reports of unspecified "logic board" problems with "Dual USB" iBooks; each has alleged that the problems are fairly widespread, and that Apple has been stifling discussion of these issues on the Apple Discussions forums. We don't have many details on exactly what these alleged problems are, but given the number of emails we've received, and similar reports we've seen around the Web, we thought it worth mentioning to see if it generates more reports with further details. (Or, conversely, to see if it doesn't, indicating that the problem isn't as widespread as some people suspect.)

This also deals with the display problem. I suggest if you want to get some action you should go to;
http://www.macfixit.com/article.php and post a comment there to reinforce that our problems are not just a few rare examples.

Good luck


New!
RE: Here we go again...another dead display
( msg # 4. : Posted Dec 24, 03 8:16 pm )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
To all of you with logic board and display problems the following is a quote Extract from MacFixit
Wednesday, December 24 2003 @ 02:29 AM PST
iBook logic board problems?

Over the past few weeks, we've received a few reports of unspecified "logic board" problems with "Dual USB" iBooks; each has alleged that the problems are fairly widespread, and that Apple has been stifling discussion of these issues on the Apple Discussions forums. We don't have many details on exactly what these alleged problems are, but given the number of emails we've received, and similar reports we've seen around the Web, we thought it worth mentioning to see if it generates more reports with further details. (Or, conversely, to see if it doesn't, indicating that the problem isn't as widespread as some people suspect.)

I suggest if you want to get some action you should go to
Êhttp://www.macfixit.com/article.php and post a comment there to reinforce that our problems are not just a few rare examples.

Good luck


New!
RE: Here we go again...another dead display
( msg # 5. : Posted Dec 27, 03 5:38 am )
Peter Hilleard
Level 1
Joined: May, 2003
Posts: 40
The Macfixit article I referred to above, inviting users with iBook logic board  / display failures (or those without problems) to posts a comment, has now been archived or taken down. Now you need to subscribe ($$) to access it.

I believe that the article and survey should have been left up for for longer ( I think it only started on 24th Dec) with easy access so more users could register their iBook status. This is especially so as it ran over Christmas when most users don't have time to  become aware of it.

I wonder what Macfixit staff concluded from the user comments received. When I last looked there were 50 replies with only 2 (I think) reporting no problems. The remainder generally had big and or  repeated failures with about half being display black out ( the hinge - cable damage problem) and the garbled screen.

Good luck,
Peter