Sony Discman D-143: Clear Audio on Line Out, Distorted Sound on Headphone Jack

Hello everyone,

I recently bought a Sony Discman D-143 for a low price, mainly to use its intact battery door as a replacement for my D-145. The seller said the D-143 wouldn't spin discs or play music.

Although it's a fairly common model from 1995 and not particularly valuable, I decided to try to save it instead of using it only for parts.

While troubleshooting, I noticed that the laser assembly moved much too freely. The cause turned out to be a broken plastic gear that keeps the laser mechanism positioned on its guide shaft. I repaired it with two-part epoxy and some reinforcing wire. After that, the laser could return to its home position correctly, and the Discman started reading and playing CDs again.

However, there was still no audio output. I replaced all electrolytic capacitors, including the two SMD capacitors, which I substituted with radial capacitors because I wanted to repair the unit using parts I already had on hand.

Now I have the following issue:

• The Line Out produces perfectly clear audio.
• The headphone jack only outputs very quiet, heavily distorted sound.

I've already checked for cold solder joints and possible shorts around the replacement capacitors, but everything looks fine.

Does anyone have suggestions on what else I should investigate?

Thanks in advance!