Art, re headphones audio level, it may be a number of things: If the
spring contact that makes to the phone tip plug gets to losing its
spring tension it might make a high resistance connection and attenuate
audio level when using phones.
There may be a solder joint that has gone bad on the wiring to the
phones jack. Cracked solder, crystalized solder, anything not shiny and
well wetted is suspect.
Start at the speaker, where you have good audio, and trace the audio
voltage back to the point of the headphone jack connections and on to
the audio stage. Record the (normal) ac audio voltage level at the
speaker line, and have it for future record.
In some receivers, they put resistors to control the amount of audio
sent to the headphones. Make sure those resistors, if present, have
values by VOM, that match their markings.
-Stuart Rohre
K5KVH
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