How to refurbish and keep an ancient Mac mini running

Older Mac minis

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On this article we’ll check out refurbishing two of the earliest Mac mini fashions from Apple: The PowerPC G4/1.42 GHz mannequin and the Intel-based Core Duo 1.66 GHz. Each machines are among the earliest “polycarbonate” mini fashions Apple made.

In truth, the 1.25GHz and the 1.42GHz fashions had been each launched on January eleventh, 2005. The 1.42 GHz mannequin was the second Mac mini ever made. The 1.42 GHz mannequin even supplied a modem port choice:

The 1.66GHz mannequin adopted on Feb. twenty eighth, 2006, and was basically the identical apart from the velocity bump and some additional ports on the again. It was the sixth Mac mini mannequin. You possibly can view complete specs on each Mac mini ever made at EveryMac.

Whereas this teardown is usually for the 1.66 GHz mannequin, the primary fourteen Mac minis had been very comparable, so most of this information applies to all these fashions as effectively.

First, we must always warning you that these machines are very delicate inside and include quite a few tiny and fragile elements. As practically twenty years have handed, their plastics are more likely to be brittle, and disassembling them at all times carries the danger of injury to parts, so proceed with warning.

You will want the next instruments to take one in every of these Mac minis aside:

A 4.5-inch (11.5cm) wall spackling instrument
A medium magnetized Phillips-head screwdriver
A tiny magnetized Phillips-head electronics screwdriver, or jeweler’s screwdriver
A small flat plastic or steel spudger
Scissors
Compressed air or an air compressor
A shiny flashlight
Shiny room lighting
Optionally a small magnifier or jeweler’s loupe
A small roll of Kapton tapeKapton tape
A CR2032 alternative button-cell battery
Sharp eyes and a gradual hand

To open your Mac mini, lay it face down on a flat floor with a skinny material beneath to forestall injury. Rotate it so the entrance of the machine is dealing with you.

Utilizing the 4.5-inch wall spackling instrument, fastidiously wedge the instrument into the machine’s case on the suitable facet between the outer steel cowl and the white plastic rim. With one movement, press down on the instrument’s deal with and to the suitable, making use of upward drive.

The suitable fringe of the case ought to come free.

Subsequent, repeat the method the identical method however on the entrance of the case, utilizing a single fast movement to pry it up.

Lastly, work the instrument into the case’s left facet on the again nook and slide it ahead to suit it totally into the case. This step is the toughest as a result of with the case now tilted, there’s quite a lot of friction and little area on the left facet.

Pry up as with the opposite two sides, till the underside of the machine comes free from the highest steel cowl. Do not take away it totally but – simply pry till the 2 halves are separated, then take away the instrument.

Now flip the machine over, and holding it with each palms, use your thumbs on the rear of the machine on the underside half, urgent it totally free from the highest cowl. You will in all probability hear a slight crunching sound as the highest comes off. Set it apart for now.

On the within, as proven within the photograph under, you may discover a DVD drive on the highest, an AirPort antenna on the again proper facet, an non-compulsory Bluetooth antenna/case sensor on the left facet, a speaker, and the button-cell battery on the entrance. The IR distant’s sensor can be on the entrance proper facet, with its cable hooked up to the entrance of the motherboard on the backside of the case.

On the DVD drive, you may be aware 4 tiny Phillips screws, and two bigger Phillips screwed alongside the left facet. The 4 tiny screws maintain the DVD drive onto the primary central plastic service, and the 2 bigger screws assist maintain the two.5-inch inner exhausting drive to the underside of the service.

There are 4 tiny screws at every nook of the primary service, and so they’re straightforward to overlook if you happen to do not look intently. Two of them are hidden down small shafts on the 2 right-side corners, and a 3rd tiny one is seen on the service on the left nook.

The fourth, and barely bigger service screw can be hidden in a small shaft on the machine’s rear left nook. Make be aware of this screw as a result of it is going to be necessary later.

On the rear of the machine is a small printed circuit board (PCB) hooked up to the rear of the DVD drive, additionally with two tiny screws. There’s additionally a small flat ribbon cable hooked up to a tiny connector on the heart of the PCB.

Additionally be aware that the AirPort antenna’s wire matches between the left facet of the PCB and the rear plastic exhaust vent.

Utilizing two fingers, very fastidiously and barely pinch the 2 small plastic clips below the AirPort antenna module and elevate up on the module. It should come free from the publish it sits on. There’s additionally a spring below it, so take away that and set it apart.

It would not take a lot drive to squeeze the 2 plastic clips to free the antenna, so do not apply an excessive amount of drive. Bear in mind, the plastics are brittle.

The antenna module is made by Tyco and has an Apple half quantity on the underside of it ought to it’s essential change it.

Subsequent, utilizing your tiny screwdriver, take away the 4 screws on each side of the DVD drive and set them apart. They’re straightforward to lose so watch out. Do not but take away the 2 tiny screws on the PCB.

Notice that the opposite finish of the ribbon cable is hooked up to the motherboard in the back of the unit so it must be freed first earlier than you’ll be able to take away the primary service unit from the pc.

Subsequent, utilizing the spudger instrument or a really skinny pastime knife pry up the tiny plastic connector holding the ribbon cable in place. This connector has two elements: a prime and backside.

Pry one find yourself fastidiously, then pry the opposite find yourself slowly whereas pulling up gently and slowly on the ribbon cable. When simply sufficient drive is utilized, the cable will come free.

One odd factor about this connector is that the small flat prime half will come fully off if you happen to apply sufficient drive as soon as the ribbon cable is free. You’d reasonably keep away from that taking place, so be very cautious and go slowly.

The opposite odd factor about this connector is as soon as the ribbon cable is re-inserted, the friction on the highest a part of the connector will increase and it is tougher to maneuver. We’ll see this in motion after we reassemble the unit under.

Utilizing the spudger or a tiny knife, fastidiously unplug the IR sensor module’s two-wire connector on the entrance of the machine, to the suitable of the button-cell battery. Be very cautious because the connector and wires are tiny and fragile.

On this photograph, from left to proper are: the speaker, case clip, battery, IR sensor connector, IR sensor:

Subsequent, utilizing the tiny screwdriver, take away the 4 tiny screws situated at every nook of the service as described above. These screws maintain the service unit to the underside of the machine’s case.

As soon as the screws are free, and holding the unit in each palms, pull up on the service unit, and press down on the underside of the machine together with your thumbs.

You will really feel a slight resistance. That is the DVD drive’s small PCB which is inserted into the SATA connector on the motherboard beneath.

Proceed urgent till you overcome the resistance and the service unit comes freed from the underside half. Additionally watch out of the AirPort antenna wire whilst you do that as it’s related to an AirPort module just below the PCB.

Set the underside half of the machine apart for now.

Subsequent take away the 2 tiny screws from the DVD drive’s PCB board.

Now that every one the screws and cable are free, you’ll be able to take away the DVD drive. It tends to need to come out on the facet reverse the 2 massive drive screws on the left facet of the machine, so gently press ahead and to the suitable facet (left facet if dealing with the machine from the again) to slip the DVD drive each out of the service and to detach it from the PCB on the rear.

Set the DVD drive apart for now.

Many of the early Mac minis shipped with a 2.5-inch customary exhausting drive. You will in all probability need to change the drive with a brand new 2.5-inch SATA SSD or a bigger capability 2.5-inch exhausting drive.

Flip the service unit over, and peel off the T-shaped foam pad on the underside of the exhausting drive. Set it apart.

Subsequent, take away the 2 massive screws on the left facet of the service, and the 2 comparable massive screws from the underside of the exhausting drive. As soon as the screws are free, solely the drive’s SATA connector friction holds it to the service.

You will have to press the drive ahead and to the left to free it from the PCB’s connector. It’s possible you’ll have to wiggle it barely to free it.

It is reasonably exceptional how Apple sandwiched the drive into the service unit.

Now, utilizing compressed air or an air compressor, blast all of the mud out of the service, the fan unit, the exhausting drive, DVD drive, and from the underside half of the pc. The seller and mannequin variety of the fan are printed on the fan’s backside facet so in case your fan has failed, yow will discover a brand new one on-line to switch it.

To essentially clear the fan effectively, it may be eliminated by loosening the three tiny screws holding it in, however it’s in all probability not obligatory. A number of robust blasts of air are sufficient to take away most mud and dust.

Additionally, be aware that the PCB by no means comes fully freed from the service because it has a number of different wire connectors and is hooked up to the rear of the service with adhesive. There is not any have to take away it until it is broken.

As soon as the exhausting drive is eliminated and all elements are cleaned, reassembly is mainly the identical steps in reverse.

Set up the brand new 2.5-inch SSD or exhausting drive into the service in the identical method you eliminated the previous one, taking care to make sure its SATA connector is firmly seated on the PCB’s connector.

Re-install all 4 drive screws, after which press the T-shaped foam strip again into place in the identical place you eliminated it from, however on the brand new drive.

Slide the DVD drive again into the service, with its rear SATA connector attaching to the SATA connector on the entrance of the PCB. Reinstall the 2 tiny PCB board screws utilizing the screwdriver.

It’s also possible to reinstall the 4 facet screws on the DVD drive now, or do it later. Doing it now makes the service unit extra steady, and it is simpler than doing it as soon as the service is reinstalled, however both method will work.

Right here is the totally cleaned and reassembled service:

Earlier than you reinstall the service to the underside of the machine, examine the motherboard, the AirPort card, its antenna cable, and different elements. Particularly verify the small spherical SMD capacitor marked “25V” on the left fringe of the motherboard subsequent to the AirPort card.

These capacitors include electrolytic fluid and are recognized to leak over time. Should you discover any corrosion or discoloration across the capacitor, it is best to in all probability change it utilizing a soldering iron, however that is past the scope of this tutorial.

Additionally, concentrate on any unusual smells across the capacitor – the electrolytic fluid inside these parts is thought to have a considerably fishy scent, so if you happen to discover any odd odors, that is the very first thing to verify.

You will additionally need to verify the tiny gold connector on the finish of the AirPort antenna cable the place it attaches to the AirPort card. These connectors are infamous for coming free simply and whenever you go to reinstall the service unit to the underside of the machine, it is simple to tug the cable off.

It is odd Apple did not safe the connector with a small strip of Kapton tape. When you have any helpful, go forward and apply a small piece over the connector now to safe it to the AirPort card.

Notice the service’s PCB board socket simply behind the AirPort card. If you reassemble the machine, you may want to ensure the PCB connector’s edge matches snugly into this socket.

Should you like, you’ll be able to improve the machine’s RAM to a most of 2GB. The specs for the RAM are listed on EveryMac, and are proven under:

Each reminiscence DIMMS have to be the identical kind and velocity, however measurement can fluctuate inside limits – for instance, a 1GB and a 512MB collectively will work positive – so long as each mixed do not exceed the utmost RAM restrict (2GB).

To take away the previous DIMMs, press gently on the 2 small steel clips on both sides whereas pulling up the DIMM and sliding it ahead, out of its socket. Watch out because the clips are tiny and may simply break off if an excessive amount of strain is utilized.

To put in new DIMMs, do the reverse: slide every new DIMM into its socket till it clicks, then press down barely to lock the clips in place.

Subsequent, utilizing the spudger or small plastic knife, take away the CR2032 button-cell battery from its socket on the entrance of the decrease half of the machine. There are two steel contacts holding it in place, so you will have to wiggle it a bit to take away it.

When you have a voltmeter, take a look at the battery to ensure it might emit 3V DC. If not, change it with the brand new one.

If you do not have a voltmeter, go forward and change the battery anyway. Make certain the “+” facet faces the entrance of the machine.

Additionally be aware the tiny copper clip simply to the left of the battery. This piece really connects to the underside of the DVD drive’s steel case, and the within entrance of the machine’s prime case, making a connection.

If this connection is damaged, the machine will not work.

The copper clip tends to return off over time because it’s solely held on by skinny adhesive on the highest of the service, and the adhesive often dries out over time. If that is true in your machine, or if the clip falls off, simply reattach it with a drop of Loctite or one other fast-drying adhesive.

There is a small peg on the highest of the service, and a small gap on the again of the copper clip which it matches onto – so it must be straightforward to line up. Discover it would not make any connection to the service itself – solely between the DVD drive and prime case.

Lastly, reconnect the IR receiver’s small two-wire plug onto the motherboard simply to the suitable of the battery.

With the underside half of the unit dealing with away from you, decrease the service down onto the underside half of the machine, ensuring the PCB board’s connectors are lined up, and that the 4 nook screw holes are lined up.

Additionally, be sure the AirPort antenna’s cable is positioned between the rear exhaust port and the small PCB hooked up to the rear of the machine. The cable has to return up via this opening, then to the left with a view to reinstall the antenna on the service:

Press down gently till the service’s PCB locks in place. Reinsert the 4 nook screws, ensuring the biggest one is reinstalled in the identical place it was faraway from.

That is necessary as a result of the screw creates a floor connection to the highest of the motherboard as soon as secured. With out this connection, the machine will not work.

Do not over-tighten the screws as it is simple to strip the threads on each the screws and the underside case. Apply simply sufficient drive to make them cosy.

That is maybe probably the most tough and fiddly step of reassembly. You will have to reconnect the service’s ribbon cable to the rear of the PCB utilizing the small clip on the PCB.

The simplest and greatest method to do that is to reposition the highest half of the connector, snap it on totally, then utilizing the spudger or a pastime knife, pry each corners again up only a bit, however not sufficient to take away the clip. Do that earlier than you reinsert the cable.

Whereas the clip is on this place, reinstall the ribbon cable into the PCB connector by urgent it gently down into place. As soon as it snaps into the connector, the highest half of the clip will likely be captive and will not come off. You possibly can then press every nook of the clip down utilizing your tiny screwdriver.

As soon as each side of the clip are secured, the complete connection will likely be strong and will not come free.

It might take a couple of tries to get the clip in place however with persistence, it is pretty straightforward. Go gradual and do not apply an excessive amount of drive. If unsure, take away the ribbon cable and begin over.

The ultimate, appropriate connection is proven under, below the suitable arrow:

Additionally be aware the place of the AirPort antenna cable, simply to the left.

Now that the service and ribbon cable are safe, reinstall the AirPort antenna onto its publish by first reinstalling the spring onto the publish, then snapping the antenna board down onto the 2 small plastic clips on each side of the publish. The antenna will lock into place.

The spring acts as yet one more safety/electrical characteristic designed to forestall the machine from working until the case is assembled: it presses down barely and makes contact, appearing like a change as soon as the case is closed.

With out the antenna module being pressed down when the case closes, it will not work.

Here is the totally reassembled Mac, apart from the highest case:

This ultimate step can be tough to get good however may be accomplished with persistence.

The primary problem in reinstalling the highest half of the case onto the underside half is the actual fact there are each plastic clips all the best way across the backside half on three sides, and there are additionally small steel clips across the rear panel on the underside half.

The steel clips additionally act like a change and should make contact with the steel within the highest half of the case.

The preliminary alignment and closure of the case are pretty straightforward, however closing it fully requires a good quantity of drive, and if every part is not lined up completely, both the plastic clips can break off, or else the steel clips can slip exterior the highest half of the case and stop it from closing fully.

If the latter occurs, the case will seem to shut, however there will likely be a small hole across the rear panel the place the highest half of the case seats towards it.

With a view to keep away from this, flip the highest half of the case face down on a floor, with the entrance dealing with away from you, then flip the underside half over and slowly decrease it into the highest half.

Test the clips on all sides, and the rear, and press down very slowly and gently, however do not shut the case fully.

After the 2 halves slide collectively, and the highest half has cleared all of the plastic clips on all sides, cease, and flip the machine on its entrance, with the rear panel dealing with up. Utilizing a flashlight, examine the alignment of the steel clips all the best way across the rear panel.

If any are exterior the highest half of the case, use your tiny screwdriver to press them down and inside the highest half.

You could have to wiggle them a bit to get the alignment good. Notice that they’re barely curved, and thus act like small springs towards the highest half of the case on the within.

You need the clips on the within, not the surface all the best way across the rear panel. What you don’t need is that this:

If this occurs, you may have to stroll the highest half of the case again off only a bit, press the steel clips in place, then reapply strain to the underside.

When you’re sure all of the clips on all sides are in good place, and that nothing is protruding, lay the machine top-down on a floor as soon as once more, and provides the underside of the case one ultimate even downward push with drive. This can seal the case – as if it had by no means been opened.

There must be no gaps on any sides, anyplace – not even tiny ones. If there are, you may want to make use of the spackling instrument to open the case once more and begin over. Take your time and watch out. Forcing the case closed will not work until every part is completely aligned.

Now that the bodily {hardware} modernization is completed, it is time to set up software program.

Reconnect the machine to a monitor through DVI or DVI->HDMI utilizing an adapter, and plug in its energy brick.

With an applicable Mac OS X set up CD or USB thumb drive prepared, energy on the machine.

It is best to hear the customary bong sound and get a gray display screen with a flashing folder. This implies the machine cannot discover an OS on any bootable drive.

Both insert a Mac OS X installer DVD or a USB thumb drive with an installer on it, and the Mac ought to detect it and boot into the set up media.

As soon as booted, you may have to exit the installer to Disk Utility, format the brand new inner 2.5-inch drive you put in as Mac OS Prolonged, then stop Disk Utility and head again into the installer.

As soon as again within the installer, choose the inner 2.5-inch drive because the set up goal and set up the OS. It might take a while in case you are putting in from DVD because the previous DVD drives are usually a bit slower.

The 1.66 GHz mini mannequin can run Mac OS X 10.6 Snow Leopard, and the 1.43 GHz mannequin can run 10.4 Tiger.

As soon as the installer finishes, click on Restart, and after the bong sound, maintain down the Mac’s mouse button. This can force-eject the DVD earlier than the machine boots. Or if utilizing a USB installer, make sure to unplug it from the Mac earlier than restarting.

The machine will boot from the inner 2.5-inch drive you put in onto. As soon as booted to the Finder, open System Preferences, and click on the “Startup Disk” icon. Set the inner 2.5-inch drive because the Startup Disk for future booting.

As soon as related to a community, you might need to additionally attempt to run Software program Replace however it’s not clear how lengthy Apple helps historic variations of Mac OS X for on their replace servers.

There are additionally downloadable .pkg installers for the updates, however you may want to go looking Apple’s help website or on-line to search out them.

The final launched model of Mac OS X 10.6 was 10.6.8 so if you happen to’re utilizing a mannequin that helps 10.6, you may need to replace to that model.

And identical to that, your newly refurbished Mac mini lives once more:

Should you’re utilizing a Mac mini which is ready to run 10.4 Tiger, it’s also possible to set up the “Basic” atmosphere which is a built-in emulator which runs Apple’s OS that got here earlier than Mac OS X: Mac OS 9.

To begin Basic in 10.4 Tiger, open System Preferences and click on “Basic”. It should boot into the OS 9 emulator and you’ll run OS 9 apps from there.

Generally, the Mac OS 9 System Folder will get put in onto the foundation of the Mac OS X boot drive alongside Mac OS X.

Notice that every one mini fashions earlier than the 1.66 GHz 2006 mannequin used ATA/100 exhausting drives, together with the optical drive (ATAPI really for optical), and the 1.66 GHz and later fashions switched to SATA exhausting drives however stored the identical ATAPI DVD drive.

If the DVD drive in your 2006-2007 mini is not working, one firm – Other World Computing – nonetheless sells new alternative ATAPI DVD drives ($48). All appropriate mini fashions have a {hardware} identifier of “Macmini1,1”.

Even when your optical drive hasn’t but failed, at that worth it is in all probability price changing it anyway, because it’s more likely to fail sooner or later, and the brand-new {hardware} will nearly definitely yield higher efficiency than a virtually twenty-year-old drive.

And it is in all probability not a good suggestion to open these previous machines too many occasions and danger injury.

OWC additionally sells appropriate memory upgrades for older minis. The 2GB improve comprising two DIMMs is a mere $12 presently.

With new RAM, a brand new SSD, a brand new optical drive, and an excellent cleansing, your retro Mac mini ought to offer you years extra enjoyment into the longer term.