SONY WM-DD series disassembly tutorial

This thread covers how to remove the cover on SONY WM-DD series walkmans: this includes the WM-D3, but also WM-2 and WM-5 (which are not DD, but share the rest of the design).
It does not apply to DD9, D6/D6C, TC-D5/D5M/D5Pro.

This tutorial has 3 main purposes:
1. To show you how to remove the back cover and cassette door latch without loosing the latch spring.
2. To show you how to disasseble without breaking REW button.
3. To show you how to reassembly.

DISASSEMBLY:
- remove all 4 screws, noting that one of them is usually longer than the other 3;
the 2 on the cassette door latch are shorter than the other 2;
- while keeping your thumb on the latch and other fingers on the head carriage, start prying to cover up from the side that contains the sticker with model number;
- at a certain point you will start encountering resistance because of FF/REW buttons; press then REW button and then the FF button just slightly; this will let your remove the cover entirely without force;
- after the cover is removed, turn the unit with the latch facing down; slowly remove the latch, so the spring remains contained in the latch;

 

REASSEMBLY:
- put the spring back into the latch;
- put the latch back onto the case, it will sit at an angle, because the spring is not compressed;
- with a thin pair of tweezers push the spring through the hole in cassette compartment in the direction of arrow;
- while keeping your thumb on the latch, install the cover starting from headphone jacks; press firmly, so the cover it fully inserted on the jacks;
- slowly push the cover, while keeping the unit tilted to the side where the switches position was chosen;
- after the cover is fully seated, double check all the switches engage with internal ones; if not, slightly raise the cover and try to move the switch to correct position; keep the thumb on the latch at all times;

NOTE: the EQ switch, Dolby switch and MegaBass switch (the last 2 are not present in all units) must be put all in the same position (either all up or all down, including corresponding switches on PCB);
NOTE2: the REW button should be pressed before re-assembly.