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How to Replace a Bose A20 GA Twin Plug (PJ) Cable

How to Replace a Bose A20 GA Twin Plug (PJ) Cable

The Bose A30 is the new kid on the block, however, the Bose A20 is still one of the best premium aviation headsets available and many pilots prefer the A20 over the A30. The A20 offers the complete package with its advanced noise cancellation, clear audio, Bluetooth connectivity, and a comfortable fit for extended use. Its lightweight and durable design, along with its intuitive controls, make it a popular choice among pilots.

Although the A20 is a durable headset, over time, and with extended use, like any other headset, it will require maintenance and replacement parts to keep going and performing at its peak. One part that tends to wear out after years of use is the control module twin plug (PJ) cable. The jacket on cable tends to develop cracks, causing internal wiring to become exposed. This can eventually lead to loss of communication mid-flight. A damaged cable on the A20 can be replaced with our new GA Twin Plug Cable. Our A20 Cable can also to be used to convert your headset from one type of plug to another such as from a U174 helicopter single plug to GA twin plugs or from 6 Pin Lemo or 5 Pin XLR to standard GA Twin (PJ) plugs. 

To get started, all you'll need is a small Phillips-head screwdriver to remove the three screws found within battery compartment, a small flat-head screwdriver to remove the cable retaining clip, and the Bose A20 twin plug replacement cable.


The first step is to remove the retaining clip that secures the cable strain relief to the control module. This can be done by using the blade on a small flat-head screwdriver. Next, open the battery compartment and remove the batteries if there are batteries installed. Within the battery compartment you will find three small Phillips-head screws. Remove the screws and set them aside along with the retaining clip.

Special Note: Version 1 (2010-2014) of the Bose A20 only has two screws not three as found in version 2 (2015 and later).


Once the screws and retaining clip has been removed, gently separate both halves of the control module housing to open the control module to reveal the internal circuit board and connectors. Disconnect the two white connectors as shown. Once this is done, unclip the wires of the old cable that you are replacing. Be careful not to break the clips. After you have unclipped both sets of wires, you can now gently lift the top circuit board to separate it from the bottom circuit board. Flip the top board over and disconnect the white connector.


After unclipping and disconnecting the two sets of white 4-wire connectors as described above, you can now gently lift the top circuit board to separate it from the bottom circuit board. Once this is done, flip the top board over and disconnect the main multi-wire white connector. You can now remove and discard the old cable.


You are now ready to install your new Bose A20 twin plug cable. Remove the new cable from its packaging and connect the white connector as shown below. After the main connector has been installed, flip the board over and reconnect and reclip the two sets of 4-wire white connectors.


Reconnect the top circuit board to the bottom circuit board. To do this, align the three holes in the circuit board to the three black pegs. Once aligned correctly, gently press on the board to get it seated and connected to the bottom. Do not apply excessive force or you may damage the pins. Once the boards are reconnected to each other,  you can now reinstall the clear plastic pieces on both sides of the control module as shown. Make sure to feed the white wire through the notch as shown below. Finally you can now reattach the top part of the housing. Be sure to insert the clip into the slot on strain relief. Gently press both halves of the housing together and reinstall the screws and clip.

Congratulations! That's it, you're done. Install batteries and test everything then go fly.

If you are not comfortable with any of the above steps, we can perform the repair for you. Click here to get started.

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