There are zillions of tutorials online to tell you how to open your iPod. The reason I put this here is that TE readers can use this thread to ask questions and share tips regarding their experiences opening an iPod. I recently found my dead 4G iPod somewhere in my cupboard. I'm not much of a music person, however the iPod was a nifty storage device. I decided to gamble about Rs275 and ordered a replacement battery from dealextreme.com (free shipping). It did take a while to arrive (almost 15-20 days) since it is shipped using general post. The battery ships with two nylon tools to open your iPod. However the tools are kinda flimsy and weak. I tried like a moron for 3 days to open the damn thing but it wouldn't so open at all. I then took it to the local computer repair dude who refused to touch it, saying he only fixes iPhones!! After much trial and error and almost resorting to metallic tools at one point I finally cracked it open.
Here is how should work for most iPods. I'm not responsible for you voiding your warranty though
1. Hold the iPod firmly in your hands with the LCD screen facing upwards.
2. Get a guitar pick (preferably the stiffest you can find)
3. Try as hard as you can to push the guitar pick in the gap between the face and metallic bottom. This is the critical part and which I got wrong a zillion times. You need to push the face plate sideways to create a gap for your pick. Patience, keep trying. When you get worked up and irritated give it up for a bit and take a deep breath.
4. Now slide the pick all around, working it bit by bit to push the faceplate away from the bottom. Be careful not to break the holding clips.
5. After you're done removing the faceplate, you'll notice that there is a wire connecting the LCD to the main board (on the bottom half). Don't touch this wire or remove it.
6. You should notice a HDD on the bottom face with a tiny IDE like connector. You can safely disconnect this but be careful as the wire is really delicate.
7. The battery should be under the HDD, it is stuck to the bottom with epoxy and can be popped out by using the guitar pick again. The wire, however, goes under the main logic board and then connects to it. To remove this wire you will need a Torx T6 screwdriver (which is part of most good screwdriver kits). You need to loosen the two screws that are at the dock end of the iPod. After loosening them you can remove the wire connector from the board and pull out the old battery.
7.1 Put back the HDD connector and try powering on the iPod with the new battery. If it works, all good.
8. Now push back your iPod cover carefully and slowly. Remember relax and take deep breaths. (If you have sweaty palms like me, this will take a while)
Congratulations, you have a fixed iPod. Don't worry if you couldn't follow the instructions to the tee, the replacement iPod battery that you order will usually come with a decent set of instructions. The important bits are avoiding metallic tools (nasty scratches) and the initial cracking open of the case which is detailed in step 3.
Do let me know if it helps or if you have any doubts.
Here is how should work for most iPods. I'm not responsible for you voiding your warranty though
1. Hold the iPod firmly in your hands with the LCD screen facing upwards.
2. Get a guitar pick (preferably the stiffest you can find)
3. Try as hard as you can to push the guitar pick in the gap between the face and metallic bottom. This is the critical part and which I got wrong a zillion times. You need to push the face plate sideways to create a gap for your pick. Patience, keep trying. When you get worked up and irritated give it up for a bit and take a deep breath.
4. Now slide the pick all around, working it bit by bit to push the faceplate away from the bottom. Be careful not to break the holding clips.
5. After you're done removing the faceplate, you'll notice that there is a wire connecting the LCD to the main board (on the bottom half). Don't touch this wire or remove it.
6. You should notice a HDD on the bottom face with a tiny IDE like connector. You can safely disconnect this but be careful as the wire is really delicate.
7. The battery should be under the HDD, it is stuck to the bottom with epoxy and can be popped out by using the guitar pick again. The wire, however, goes under the main logic board and then connects to it. To remove this wire you will need a Torx T6 screwdriver (which is part of most good screwdriver kits). You need to loosen the two screws that are at the dock end of the iPod. After loosening them you can remove the wire connector from the board and pull out the old battery.
7.1 Put back the HDD connector and try powering on the iPod with the new battery. If it works, all good.
8. Now push back your iPod cover carefully and slowly. Remember relax and take deep breaths. (If you have sweaty palms like me, this will take a while)
Congratulations, you have a fixed iPod. Don't worry if you couldn't follow the instructions to the tee, the replacement iPod battery that you order will usually come with a decent set of instructions. The important bits are avoiding metallic tools (nasty scratches) and the initial cracking open of the case which is detailed in step 3.
Do let me know if it helps or if you have any doubts.
They charge 1k or something. Better than throwing it away 
hyeah: 
