This is why iPOD mini makes static cracking noises
My iPOD mini after two weeks of gentle use started to make horrible static noises; sometimes sound will disappear completely. Then the sound will return to normal, but any pressure as small as thumb pressure anywhere on iPod mini will make sounds to come back. Resetting iPod did not help.
Guided by the detailed ?iPod mini Autopsy? posted here on iPodLounge, I disassembled by iPod rather easily. To check the reason of these noises, I started to play the iPod and disconnected the wheel, then the hard drive, but iPod was still playing (out of 25 min flash memory) and still making noises.
Eventually, I narrowed the problem to a small little part that contains headphone and remote jack and metallic part in the shape of the white plastic top.
This small part attaches to main iPod board ONLY via small black connector that sits on on the main board. What an OVERSIGHT on Apple?s ENGINEER"S part!
Theeir mistake is obvious. The small part with the headphone jack attaches via screews to the aluminium case, but does NOT screw to the MAIN board. Because of this any pressure on iPod case, dock connector, or simply plugging in and out headphones, creates TENSION between the small part and the MAIN board.
Since only the black connector sits between these two parts, it quickly wears out.
What is even worse is that the black connector is attached to the main board via ten very fragile copper pins that stick out of the main board (sorry for not using proper electronics terminology). With regular use, contacts get loose and slightest pressure on iPod creates nasty squeaky static type noises killing all the joy iPod brings.
I am sure this problem will surge in time. Future iPOD minis need to have the part with headphone jack screwed to the main board (not just to the case like it is on current MINIs) OR to use FLEXIBLE cable. To rely on ten tiny fragile pins is just plain irresponsible.
If you have the same problem, I do NOT advise you to take apart iPOD. The copper needles that stick out of the main board are very very brittle and once broken will require replacing the entire board.
Here are some picks about the connection taken from my new mini. Picture links are inside a parody love story

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http://www.math.unl.edu/~iloladze/iPod.htm