How to Disassemble the Bose ProFlight Series 2 Aviation Headset to Fix Poor Audio, Earbud Alignment, and Comfort Issues (DIY Teardown and Repair Guide)

Does your Bose ProFlight Series 2 headset have worn-out earbuds that refuse to seal? Does the ANR (Active Noise Reduction) work intermittently, or does the boom mic make weird noises when you rotate it? If you’re experiencing any of these issues, it’s time to replace the failing components.

In this DIY teardown tutorial, we show you how to disassemble your Bose QC Ultra headphones and complete the necessary repairs at home with genuine spare parts.  Below, you’ll find all the tools needed for this repair, along with OEM replacement parts.

Prefer to get your earbuds professionally fixed? Send us your Bose ProFlight Series 2 aviation headsets using our mail-in repair service, and our repair ninjas will restore your device to peak working condition. You don’t need to pay upfront. We only charge after repairing your device.

Fill out our repair form to receive your free prepaid shipping label, then send your device. We’ll take care of the rest.

Repair Difficulty

Moderate / Requires 45-60 minutes to complete.

This repair involves carefully disassembling the Bose ProFlight Series 2 aviation headsets to reveal the problematic components and replacing them with genuine spare parts. While prior soldering experience may be useful, it’s not mandatory. With a bit of patience and attention to detail, you can replace the failing components at home.

Replacement Parts You’ll Need

Restore the form and functionality of your Bose ProFlight Series 2 aviation headsets with genuine spares. Select the OEM replacement parts from the drop-down menu below to bring your device back to peak working condition.

• Genuine Bose ProFlight Series 2 Aviation Headset Replacement Parts – OEM

• Amtech Inventec NC-559-V2 Tacky Solder Flux 10CC + Curved Tweezers For Micro Soldering Repair - Kit

Looking for another spare part? Browse Joe’s GE Parts Catalog for the Bose ProFlight Series 2 to find genuine replacement parts for your headphones.

Tools You’ll Need

Before starting the Bose ProFlight 2 teardown, gather the following tools. Using the correct tools will help you disassemble the device and replace the failing components successfully. We used the following tools and recommend them for a safe, professional-quality DIY fix at home.

• Joe’s 50-in-1 Precision Screwdriver Kit
• Precision Tweezers
• Nylon Spudger
• Heat Gun
• Soldering Iron
• Soldering Flux
• Heat-proof Anti-skid Rubber Work Mat

Don’t want to DIY? Let our certified techs handle the repair. Book your repair now.

Step-by-Step Bose ProFlight Series 2 Aviation Headset Teardown and Repair Guide

In this detailed DIY tutorial, we show you how to disassemble and repair the Bose ProFlight Series 2 aviation headsets yourself. Follow each step carefully and use the accompanying images as a visual guide to complete the repair with confidence.

Step 1: Disconnect the Boom Microphone

Disconnect the boom mic from the left side of the headset by pushing the tab as you pull the mic, then set it aside.

Step 2: Disassemble the Left and Right Headband Slider Panels

The steps are similar for both sides. We'll highlight any differences you need to know for each side.

2.1. Unfasten the 2 screws securing the two slider assembly panels with an S2 PH0 screwdriver from the Joe’s 50-in1 precision screwdriver kit.

2.2. Push down on the tab on the right side, similar to step 1, to release the cap, then set it aside.

2.3. Insert a nylon spudger dipped in isopropyl alcohol under the top plastic tab securing the two headband slider panels, then gently work the tool on all 4 sides till the tab pops off the retaining clip.

2.4. Once the top plastic tab comes off, insert the nylon spudger into the seam between the inner and outer panels, and work your way around the perimeter till the two halves separate.

2.5. Peel the heat tape covering the main ribbon connector, then unplug the ribbon cable from the PCB with a nylon spudger.

Step 3: Extract the Left and Right PCB from the Housing

The steps are similar for both sides. We'll highlight any differences you need to know for each side.

3.1. Apply gentle heat over the solder points for a few seconds at a time to soften the adhesive before scraping them off with precision tweezers. Do not heat one area for several minutes, since that may damage the PCB and melt the surrounding plastic.

3.2. Spread the wires connected to the PCB with your fingers and take a photo of the connections to use as a reference during resoldering. Apply soldering flux to the connections, and desolder them.

Ninja Repair Tip: If the wires refuse to come off the PCB, use soldering wick. Alternatively, you can flip the PCB and desolder the stubborn wire from the other side.

Step 4: Separate the Left and Right Earbud Assembly from the Rotating Mechanism

The steps are similar for both sides. We'll highlight any differences you need to know for each side.

4.1. Remove the arrow sticker and set it aside.

4.2. Flip the plastic housing over, apply gentle heat with high airflow onto the socket where the earbuds are glued onto the housing, then gently pull on the earbud wire to separate the two parts.

Congratulations! Your Bose ProFlight Series 2 Aviation Headset Teardown Is Complete

You have completely disassembled your Bose ProFlight Series 2 aviation headset down to its individual components. Replace any damaged or malfunctioning parts with genuine OEM spares, then reverse your steps to reassemble the headphones and restore them to full working condition.

If you found this guide helpful and would like to try your hand at DIY gadget repair, visit our store for essential tools and spare parts. You can also check out our at-home DIY headphone repair guides for other popular brands, including Apple, Beats, Bose, and Sony.

Have questions or suggestions about this repair? Text a repair ninja or email us, and we’ll reply shortly.