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There are several ways the Bose amps commonly fail. The most common seems to be leaky caps. (capacitors)The usual symptom is a "popping" sound as music is playing. Localize the popping to which speaker it is coming from then dive in.
This "How To" covers.
  • Removing the rear amp
  • Replacing the electrolytic caps
Six screws holding in the bezel.
Bezel off view.
Gently pull up the side carpet starting at the bottom.
Remove the six 7mm hex head screws holding in the speaker/amp cabinet.
I show detail here to stress the importance of finessing the carpet up.
When doing the middle one, don't let the socket slip down in there!
Disconnect the amplifier connector.
Remove the four phillips head plastic thread screws.
Notice handy place to store screws on magnet.
Not shown, remove the four screw holding in the speaker and disconnect the two wires attached to the speaker. Then place the board in a suitable holder for desoldering.
Use solder wick to remove the solder around the caps.
  • two 4.7uf 16V
  • two 1uf 16V
  • one 47uf 16V
  • two 1000uf 16V
  • two 10uf

All are going to be either 85deg C or 105 deg C. The temperature rating is not what is killing these caps. It is the voltage rating margin. I used 25V rating on all replaced components.

Use hot air gun to melt the glue (it is hot glue gun glue) As you do this use a small flat blade screw driver and needle nose pliers to grab the slightly fluid glue.
Notice the chunks of glue to the bottom right in the photo above.
Here you can see the empty space now between components where once there was massive quantities of glue.
Touch the back side lead of each cap with a soldering iron and they will just fall out. Do just one cap at a time so you can pay attention to both the value AND the polarity. Make sure you get the right value in and WATCH THE POLARITY!
Reassemble and test. This procedure has worked for me on two amps now.
Other Links:
Bose Amp Repair
Author: Scott Fabre
Posted in: Electronics
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