The cable on a pair of headphones suffers more abuse than most audio cables. It is exposed to far more repetitive movement than many, it has to be reasonably thin and not too heavy. As many a newbie studio tech used to find out, the design also makes a headphone cable the devil's own job to solder to.
The most common fault to befall a set of headphones is the intermittent loss of one channel. In most cases this is because, despite the special construction, there has just been too much flexing of the cable and the strands have broken. This seems to be particularly the case with the standard moulded plug that has become popular over the last decade or so, and aggravated by the shift to 3.5mm plugs over larger 1/4 jacks.
Diagnosing Intermittent Headphone Problems
Careful flexing of the cable and listening to the fault usually shows that the break is close to where the cable exits the plug. The good news is that a repair doesn't have to lose much of the cable.
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