Apple iPod Classic 5th Gen (120GB) Battery Replacement With Original HDD

If you’re rocking an Apple iPod Classic 120GB (5th Gen Enhanced) and it’s dying fast, shutting off randomly, or only working while plugged in, you’re almost always looking at a worn-out battery. The good news: this model is still very serviceable—no heat, no glue, just careful opening and clean handling of the internals.

This post covers how we replace the battery in a 120GB iPod Classic with the original hard drive still installed, plus the common gotchas that can turn an easy job into a broken housing or pinched cable.

Symptoms of a Failing iPod Classic Battery

Most battery failures show up as:

• Drops from full charge to dead quickly
• Shuts off when skipping songs (HDD spins up and voltage dips)
• Won’t power on unless connected to a charger
• Battery percentage jumps around or gets “stuck”
• Takes forever to charge and still doesn’t last

With an original HDD iPod, weak batteries are even more obvious because the drive needs extra power to spin and read.

What You Need

Parts

• Replacement battery for iPod Classic 120GB (5th Gen Enhanced)

Important fitment note (120GB + original HDD):

Because the original hard drive takes up space, you typically can’t fit the extra-thick “extended” batteries unless the iPod has been converted to flash storage. For an original 120GB HDD build, you usually want the standard/thin battery that matches stock fitment.

Tools

• Plastic iPod opening tool / thin spudger
• Small Phillips driver
• Tweezers (helpful for routing)
• Optional: Kapton tape / thin double-sided tape

What not to use

• Metal screwdriver for prying (easy to gouge the case and short components)

Step-by-Step: Battery Replacement (120GB 5th Gen Enhanced)

1) Power Down and Lock It

• Slide the Hold switch ON (orange showing)
• Disconnect any cable

2) Open the Housing Carefully (Clips Around the Edge)

The Classic uses internal clips all around the perimeter.

• Start on the right-hand edge (usually the easiest entry)
• Insert a plastic tool between the front and back shells
• Pop clips one at a time—work slowly around the edge

Shop tip: The back shell bends easily. If you pry too hard, you’ll permanently warp it or crease it. Think “clip release,” not “can opener.”

3) Open Like a Book — Don’t Yank

Once the clips release, open the iPod gently. You’re going to see the battery and the internal assemblies.

On this model, you can usually open it enough to work without fully removing everything, but always move slowly—there are cables and connectors that don’t like being stretched.

4) Disconnect the Battery From the Logic Board

Find the battery connector on the logic board and unplug it:

• Use a spudger to lift the connector straight out
• Never pull the wires—that’s how battery leads get torn off

5) Remove the Old Battery

The battery is commonly lightly adhered.

• Lift it slowly
• If it’s stuck, work a plastic tool underneath
• Don’t puncture or bend the battery (swelling and failure risk)

6) Install the New Battery (Stock Fitment for HDD Builds)

• Place the new battery in the same position
• Route the cable cleanly so it won’t pinch during closure
• Plug the connector back into the board

120GB HDD reminder: If you try to force a thicker battery into an original HDD build, the iPod often won’t close—forcing it can pinch the cable, stress the frame, or pop the clips back open.

7) Test Before Closing

Before snapping the housing shut:

• Toggle Hold off
• Power on (Menu + Select if needed)
• Confirm: boots, scroll wheel responds, and it starts normally

If it doesn’t power:

• Re-seat the battery connector
• Confirm Hold isn’t still on
• Plug into power for a few minutes and retry

8) Close the iPod

Align the frame and press around the perimeter until the clips snap in.

If it won’t close smoothly, stop and re-check:

• cable routing
• battery position
• anything sitting proud of the frame

After the Repair: Battery Calibration

For best battery reporting accuracy:

1. Charge to 100% (leave it another 30 minutes)
2. Use it until it shuts off
3. Charge uninterrupted back to 100%

Why This Repair Matters More on an Original HDD iPod

The original hard drive draws more current than flash storage. A weak battery can’t supply stable power, so you get:

• random shutdowns
• freezes during song changes
• boot loops
• “dead unless plugged in”

A fresh battery restores stability, not just runtime.