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So, you're among the thousands who think that the new Xbox 360 Headset sucks burro balls compared to the old Xbox Headsets huh? You know you can't hear jack sh*t out of the new headset compared to the old ones and you want to do something about it. You also know that you can plug the old Xbox Headset or a Halo 2 Headset into the 360 Controller but if you do that then you will have NO Mute and NO Volume Control, and that sucks too right? Well, here's what you can do that will enable you to use your old Xbox Headset (or a Halo 2 Headset) with your new 360 Controller while still being able to use the Mute and Volume Controls...
***WARNING: Doing This Procedure Yourself May Result In Two F*cked-Up Headsets (your old Xbox Headset and your new 360 Headset) So Please Either Follow These Instructions Correctly Or Else Do Not Attempt To Do This. The Instructions Below Are For Switching To The Old Xbox Live Headset But This Procedure Can Also Be Used On Halo 2 And Other Headsets As Well ***
STEP 1: Take It Apart
Unscrew the 2 screws from the grey 360 plastic housing module and take it apart. Note the 4 wires...

STEP 2: Unsolder The Wires
Touch the tip of a soldering iron to the solder joints of the 4 wires, one at a time, pulling each wire out of the solder joint while you heat the joint. It will only take a second for each joint to be heated enough to remove the wire...

STEP 3: Pull Out
When you have all 4 wires removed, pull the whole wire assembly through the plastic housing and remove the two rubber grommets...

STEP 4: Cut The Wire
Now take a blade or some snips and cut the old black/green Xbox Headset wire somewhere around here...

STEP 5: Put Her Back Together
Strip the outer cover of the black/green wire harness back about 3/4" at the end to expose the 4 inner wires. Feed the whole wire harness through the hole in the plastic 360 controller housing and get ready to solder. The red, blue and gold wires you can just leave alone but on the white wire you will need to strip about 1/4" of insulation off the end so you can solder it (the other 3 wires are already striped so don't worry about those). Now, one at a time, while looking at the picture in "Step 1" above or the picture below, carefully solder each of the 4 wires onto the solder joints on the 360 circuit board that you took apart earlier. You do not need to use any additional solder, all you have to do is heat up each solder joint (one at a time) and stick the new wire in the correct solder joint (one at a time).
READ FIRST: You will need to solder the RED wire where you unsoldered the BLACK wire. In otherwords, solder each wire like this:

STEP 6: Crimp Or Knot The Wire Harness
Now take the plastic housing and loop it into itself and make a knot. Move the knot down to the end of the wire harness and then pull both ends to make the knot as tight and as small as possible.

STEP 7: Admire Your Handiwork On Your Headset (Or Mutilation Thereof)
Put the two plastic housing pieces together with the two screws. You will now have no rubber grommets inside the housing which protects the wire harness from being pulled out (the old Xbox wire harness is too thick for the rubber grommets), but that knot that you made on the end of the wire harness (inside the housing) should do the trick and prevent the wire harness from being pulled out. You can also use a small crimp on the end of the wire harness instead of the knot - your choice.

Well hopefully you didn't f*ck up your headsets by trying this but if you did, oh well, a new 360 headset is only about $20. I'm no expert at this kind of thing and I'm sure more knowledgeable people can figure a better way to do this procedure (or even improve upon what i have done) but if you followed these instructions correctly it should work A-OK for you (it did for me).
Only adults should try this and if you do attempt this procedure you do so on your own risk and initiative and I am not liable for any
measly $20 headsets made inoperable by your destroying them via my headset-swapping instructions above, nor am I liable if you
solder a hole through your finger or if you drop your soldering iron and burn up your carpet while trying this inebriated. Biotch.
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(P.S. You can also do this procedure using a nice Halo Headset or some other Headsets as well. Check out the killer job that gamer "XtremeBug" did with his Halo Headset. Oh and, I guess you can leave the one rubber grommet sticking out of the plastic housing like XtremeBug has done (probably need to do it before you strip the end of the wire harness and then force it in the rubber grommet) -- see, I KNEW some guys would come up with some improvements on this!

(P.S.S. If you don't like to solder or if you have no soldering iron you can also do this procedure without soldering by simply cutting the old black headset wire harness near the end and then cutting the new 360 headset wire harness near it's end, then exposing the 4 wires on each harness, then fusing all 4 wires together with black electrical tape or butt-splice connectors. This method would not look as good, however, as the soldering method.)
- Xenergy
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