Link to Apple support forum thread for this problem: https://discussions.apple.com/thread/3545978
This is video of a problem I've recently started having. Sorry for the poor quality/choppiness; I had to try and recreate this problem one-handed while filming with the other.
Plugging headphones into my iPhone 3GS causes the volume to max out without me increasing it, which is obviously very annoying; if I rotate the plug the volume decreases, but still remains at a louder volume than where it was before I plugged in the headphones.
Additionally, if the headphone plug rotates while it's in the jack (e.g., if I have it in my pants' pocket and I'm walking or sitting/standing up) the volume also changes: sometimes it goes down and sometimes it goes up.
If I use non-Apple headphones, however, the volume maxes out and just stays maxed out, even if I rotate the headphone plug.
Any thoughts? Do I need a new headphone jack on the actual iPhone?
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