Firstly remove the screen after taking the hinge cover plate off. But first carefully remove the ribbon cable from the screen where it pushes into the MB. It is clamped by a rectangular plastic plate that lifts off. Remove all components underneath that you can see, ie. Battery, HDD, CD/DVD unit. Remove all visible screws on the underside that are not only in the bottom exterior but the silvery internal well area. Having done this, the top and bottom halves will almost part, but with care because there is another ribbon cable (white) from top half top the bottom half. This unplugs from the MB. Expecting now that you have struggled to get this far, you will want to get at the CMOS backup battery? Oh ho! Assuming that you are looking down on the MB at this time, look at the top RH corner, see the 2 screws near the IR unit? Remove those and the IR unit. Next, turn the laptop,(what's left of it) so that you are looking at the rear panel. Take out all the hexagonal port fixing sockets/screws. Now lift out the port daughter board, it is plugged into the the MB. Also while you are there look to the LH end of the rear panel and there are 4 tiny screws to remove. Don't lose them! Here I must mention that on reassemble, the power slider switch slider on the back RH end needs to be carefully located back on the switch, a fiddly job! Keep your eyes peeled since there will certainly be something I have missed but it will only be a cable that is plugged into the MB. Note: The gold coloured ribbon cable from the screen to the mother board is firstly released before the screen screws are removed. A small plastic rectangular plate under the keyboard can be lifted off carefully to reveal and release the gold ribbon cable. I thought I would mention that again!!! Great care here please. This thing has to work again later LOL! The CMOS backup battery is on the underside of the motherboard. It is clad in a plastic/rubber like cover. The MB will need to be released by taking out 4 screws. 2 at the rear and 2 at the front. Look out for additional cables and the small speaker. The battery is not removable, supposed to have a life of 10 years! It is disconnected by pulling off the small plug from the nearby socket. To discharge the battery completely, it is advised to leave it unconnected for 30 minutes while you have a cuppa. Now there will be no need of that darned password ever again (unless you are daft enough to want one!) I take it that you will be familliar with the mechanics of the internal parts of a laptop? Well not many people are in reality. I would hope that it all goes back properly and nothing is lost or displaced (such as the rear door spring catch!) That can easily be squashed between the upper and lower halves. I assume that the toughbook is still quite tough? Check everything!+++ ..Switch on and go into the CMOS settings and from there ensure for your own sake that the bootup sequence is the 3rd option. Floppy, CD/DVD and drive C: Then you can read a setup CD for a reinstallation. I wish you all the very best of luck. Cheers. from John, Hi-Spec-Tek.
John Baxter. Hi-Spec-Tec., March 2008
