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Sony Laptop Charger Repair- Intermittent Problem

By on September 3, 2016
how to fix sony laptop adapter









Customer walked in to my workshop wanted me to repair his Sony Laptop. The complaint was the charger because sometimes it can charge the battery and sometimes not charging. What I did was to connect the power adapter to the Laptop and powered it ON.

I found the LED power indication on power adapter was ok but power indicator LED on Laptop was not lighted up. Hence I have used my multimeter to test the power output of the power adapter. As per specification on the adapter the output is 19.5 V DC.

sony laptop charger repair

Testing voltage of the output jack of the power adapter, I’d got .03V instead of 19.5 V DC, so this reading confirms the problem with the adapter.

sony laptop power adapter repair

After this result I have decide to open the adapter for further troubleshooting. After opening the adapter, as usual I found pastry cream spilled on components (Ha ha hah!!!!…………….. Just joking). This white substance is used as Thermal Paste Glue on the components where chances of overheating are high on applying the Load.

sony power adapter repair

On visual inspection I have not seen any Burnt marks and physical damage. As power LED light indicator is working on the adapter this means some voltages are available up to the LED area hence it is time to test voltages on the other end of the DC Pin wire on the PCB where they are soldered.

how to fix laptop charger

Here I got 19.8 V DC that means adapter is ok and problem is in between adapter DC wire and DC Pin. Now the job starts here to find break in between.

fixing laptop adapter

On testing the cable I found cut type twist near cable grommet of the adapter, so I have again tested output voltage on DC pin by twisting and shaking the cable but no effect on reading. Hence I cut the wire for further testing and tested wire to the pin by continuity tester one wire is showing continuity and other wire does not (Wire is open circuit somewhere) that means culprit is not grommet area but somewhere else.

Now what? Because I can arrange the wire if found bad but what about the pin. Because this type of DC Pin is difficult to find in the market and buying it on line is not worth. So here I have two options one give back the adapter to the customer unrepaired or try “something else” so that I also make some money and customer is also be happy by retaining the original power adapter.

So what is that something else?

With the help of Non Contact Voltage Detector pen I have traced the wire by applying AC 230 V (while doing this please use insulation tap on other side end of the wire under test) in this process the device shows full continuity till the end of the wire DC Pin. Hence chances of the damaged DC pin is high,

laptop jack problem

Hence I have cut the DC Pin from the wire and again I have tested the continuity on the wire by using multimeter. Now I got the continuity on both the wires that mean wires are OK and DC pin (output jack) itself is culprit. As you can see the pin is molded and sealed in plastic grommet. Now this is time to modify the pin.

I have used nail remover pliers for cutting the plastic grommet and removed the metal unit and removed old solder and wire from the pin and soldered the cable which I have tested for the continuity again on the pin. After solder I tested again this cable from pins to the other end of wire found OK. Now it is time to reallocate everything back hence prepared the wire with grommet-for final work.

how to repair sony laptop charger

Now till here every thing is smooth now what about the DC Pin. How to cover the pin because you cannot use the same grommet back which you have removed so I have used a product called M-Seal to cover the pin. Sorry for not covering the photograph of the process because I have to use my both the hand and palms are become sticky while mixing up the material of M-seal and making clay out of that and here is final touch up on the pin.

laptop jack fix

Now the things are totally modified and ready for the final test.

fixing laptop charger

repairing sony laptop charger

On final testing I’d got 20V DC without load that means the Sony laptop charger (power adapter) is repaired.


This article was prepared for you by Yogesh Panchal who works as a Computer Hardware Engineer in Mumbai India.

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Note: You can check his previous repair articles on LCD Monitor in the link below:

Acer Aspire 5560 Laptop Repair- No Power



  1. Parasuraman

    September 3, 2016 at 5:10 pm

    Good job!

    • Yogesh Panchal

      September 4, 2016 at 12:22 am

      Thank you Sir.

  2. Albert van Bemmelen

    September 3, 2016 at 5:34 pm

    Nice job Yogesh. Here in Holland we can now buy something new and maybe similar to the M-Seal product you mentioned. It is called jml-5-second-fix with a special glue that fixes anything, even leaky waterpipes. It is sold with an UV activating Light Pen. I've not tested it myself yet because almost 15 euro isn't quite cheap. And you can re-use the Pen by buying Glue Refill Sets too.

    • Yogesh Panchal

      September 4, 2016 at 12:35 am

      Thanks for comment.
      M seal become Rock solid within 8 hrs. and yes you are right this is used for Plumbing for leaky water pipes it gives you instant result just apply and dripping get stop instantly and price around .40 euro

      • Albert van Bemmelen

        September 6, 2016 at 12:01 am

        Thanks Yogesh. I will see if also M-seal is obtainable in my country.

        • Albert van Bemmelen

          September 7, 2016 at 3:55 pm

          Hi Yogesh, I wrote UV Pen, but the better English translation would probably be that jml-5-second-fix looks like a refillable Ballpoint. But Google probably shows exactly how it looks.

  3. suranga bandara, Suranga Electronics

    September 3, 2016 at 6:56 pm

    Hi Mr-Yogesh,

    Good job! Keep sharing.

    • Yogesh Panchal

      September 4, 2016 at 12:36 am

      Thank you suranga.

  4. Bulent NUR

    September 3, 2016 at 7:51 pm

    Thank for sharing!

    • Yogesh Panchal

      September 4, 2016 at 12:36 am


      You are welcome.

  5. chelseabun

    September 3, 2016 at 8:13 pm

    it is really not recommended to use such that poor multimeter on line voltage. i think you should considering another multimeter for safety

    • Yogesh Panchal

      September 4, 2016 at 12:39 am


      Thanks for your concern, but i am using this meter since last 5 Years without any problem.

  6. Charlie

    September 3, 2016 at 8:32 pm

    I have often encountered this very same problem. It's seems the cable breaks way more often than the power supply goes bad.
    Had never heard of M Seal and I don't know if it is available in the U S, but if it cures strong enough this seems to be a great use.
    I have a 2 part epoxy for plastics which may be similar.
    Thanks for the repair info and the inspiration.

    • Yogesh Panchal

      September 4, 2016 at 12:47 am


      Thanks for comment. you can use any "non conductive" substance which fulfill your purpose that the only thing matters.

  7. Robert Calk

    September 3, 2016 at 8:43 pm

    Good job, Yogesh.

    • Yogesh Panchal

      September 4, 2016 at 12:53 am

      Thank you Sir.

  8. Mohammed Aly

    September 3, 2016 at 10:53 pm

    hello sir. could you please tell me how can i test the components under the white thermal glue ?

    • Yogesh Panchal

      September 4, 2016 at 12:58 am


      You have to remove the Glue with knife or flat screw driver by using it gently.Be careful and discharge the high value Capacitor before touching any parts.

    • Robert Calk

      September 4, 2016 at 7:38 pm

      Also the glue is easier to remove after you warm it up some.

  9. Andre Gopee

    September 3, 2016 at 11:35 pm

    Nice repair article Yogesh. Thanks for sharing.

    • Yogesh Panchal

      September 4, 2016 at 12:59 am

      Your Welcome.

  10. Humberto

    September 7, 2016 at 12:20 am

    Hi Yogesh, nice repair. You acted good and professionally, it's better to repair the original Adapter than buy a cheap one which most of the times are poorly made.

  11. Ulises Aguilar Pazzani

    September 10, 2016 at 8:48 am

    Mr Yogesh nice repair and very ingenious

  12. Ahmad Hossain

    June 29, 2018 at 1:44 am

    Suddenly sky is Thundered and then my Sony 19.5 volt 3.05Amp adaptor not working .

    Sir why adaptor is not working
    help me please.

  13. Ashutosh verma

    July 18, 2019 at 6:34 pm

    Nice article Mr Yogesh.I would like to ask that in my sony laptop adaptor one component a round coil form just besides the input connection has gone black.What is the name of it and where i can buy it.plz help .


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