How to Replace a Broken Battery Cover on a Bose A20 Aviation Headset

A broken battery cover is one of the most common issues we see on the Bose A20 and it’s also one of the easiest repairs you can make. With a new replacement battery cover and a few basic tools, you can have your headset looking and working like new again in just a few minutes.

At Hobbs Flyer, we believe in Keeping Great Aviation Headsets Flying™. That’s why we develop high-quality replacement parts, repair services, and retrofit solutions that help pilots extend the life of the equipment they already know and trust.

Tools Required

Before getting started, gather the following:

• Phillips screwdriver
• Small pair of needle-nose pliers
• New Bose A20 Battery Cover
  

Step 1: Open the Controller

Open the battery compartment and remove the screws securing the controller.

There are two versions of the Bose A20 controller:

• Generation 1: Remove the two Phillips screws inside the battery compartment.
• Generation 2: Remove the three Phillips screws inside the battery compartment.

Once the screws have been removed, carefully remove the spring clamp that wraps around the controller where the headset cable enters.

With the clamp removed, gently separate the two halves of the controller

Step 2: Remove the Battery Cover

Carefully flip the top half of the controller over.

Inside the battery compartment you’ll find the rubber battery cover tether attached to two small plastic posts.

Using a pair of needle-nose pliers, gently lift the rubber tether off one post and then the other.

Take your time here. The plastic posts are durable, but there’s no need to force anything.

Once both ends of the tether have been released, remove the broken battery

Step 3: Install the New Battery Cover

Insert the rubber tether of the new battery cover through the compartment opening in the controller housing from the outside.

Feed the tether through the battery compartment until it reaches the two retaining posts inside the compartment.

Using your needle-nose pliers or your fingers, press each end of the tether onto the plastic posts until it

Step 4: Reassemble the Controller

Place the controller halves back together, making sure no wires are pinched between the housing halves.

Reinstall the spring clamp around the cable entry point.

Finally, reinstall the battery compartment screws.

Do not overtighten the screws. Tighten them only until they

Step 5: Test Before Flying

Install two AA batteries and verify that the battery cover opens and closes smoothly and latches securely.

Power on the headset and confirm that Active Noise Cancellation operates normally.

Once everything checks out, your Bose A20 is ready for many more years of flying.

Keeping Great Aviation Headsets Flying™

A broken battery cover doesn’t mean it’s time to replace your headset.

At Hobbs Flyer, we believe in Keeping Great Aviation Headsets Flying™ by developing high-quality replacement parts that make common repairs simple, affordable, and reliable. With just a few minutes of work, you can restore your Bose A20 and get back to doing what you enjoy most—flying.