When dismantling any phone, great care should be taken to ensure that no damage is caused to any of the parts. Rough handling may result in severe damage of many parts, and if proper anti-static procedures are not followed, electrostatic damage may result in any electronic component.
Before commencing, it is recommended that the correct tools are purchased for the job in hand - at the very least, you will require a Torx T8 screwdriver..
Step 1. Remove the battery cover, battery, stylus, SIM card, flip and your memory stick (if fitted).
Step 2. The next step is to remove the aerial cover. On the top of the phone where the front and back fascias meet, insert a thin piece of plastic at the point marked in red. The aerial cover is latched at either side of this point, so use the plastic shim to gently but firmly release the latches. Once this has been done, you need to release the cover at the points marked in yellow. This is relatively simple as the cover only latches quite loosely at these points.
Step 3. With the aerial cover removed you can see the four main screws (marked here in red) that hold the phone together. Using a Torx T8 screwdriver, remove these screws and keep them in a safe place. Please note that on the screw directly below the handset identification sticker there is a small metal battery retaining clip which will come away once the screw is removed. This is very small, and you should take note of its orientation prior to removal.
Step 4. Now comes perhaps the trickiest part of the operation. The back fascia is simply clipped in place, but is awkward to remove. The correct method for removal is to use a thin plastic shim inserted through the memory stick socket to release the two clips from their retaining lugs. DO NOT simply apply brute force to rip the casing open, as once the clips have been separated you will need to disconnect the jog-dial connector from the main board by simply prising it away. An alternative method to separate the housing is to use a thin shim of plastic and slide it around the phone starting at the base and working up the side containing the memory stick socket. With this method, make sure not to insert the plastic too far inside the phone or you could cause damage to components you can't even see.
Step 5. Now that the housing has been separated, take a look inside the back housing. In the picture below you can see the camera shroud, vibra motor, headphone socket and the camera & WAP button assembly removed from the housing. You can also see the jog-dial assembly which has not been removed due to this one being glued in place due to prior damage. Normally this is simply slipped in place and can be removed easily. The other item which has not been removed is the speaker. If you do want to remove this, please note that it is stuck in place and you will require a new gasket and foam spacer when you fit it back in place.
Step 6. Your next step is to remove the main circuit board and screen assembly. Observing anti-static precautions, release the screen connector by gently prising it up and away from the main board. Next, release the two clips and lift the main board out from the front fascia. Finally you will be able to simply lift the screen out from the fascia.
Step 7. If you've followed the steps above properly, you should have the fascia, screen and main board separated as shown below. Take care when handling the screen not to leave finger marks and dust which will show when you reassemble the phone.
Step 8. Reassembly is a simple reversal of the above steps, and is a lot simpler due to not having to release the front and back fascias. Do remember to reattach the screen and jog-dial connectors at the right point, or you will be disassembling the phone all over again. Once the phone has been reassembled, test it thoroughly to ensure that you have reassembled it correctly, and also that you have caused no damage whilst the phone is apart.
Source : uselessinfo.pwp.blueyonder.co.uk
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