Audio Systems: Car Audio, needle nose pliers, digital amp


Question
         Ok this is what happened I have a CD player, power cell, digital amp, and subs in my car all where working fine for about 4 months but 2 days ago the subs would cut out with low volume. I turn it all the way up (30-35) and they work fine but if I turn it down (0-29) they cut out and play when they want to. The lights on the power cell and amp stay on and everything in the trunk looks good just by glancing at it.

         Then I thought it might be the CD player, well I unhooked It and messed with the RCA's and remote wire but still it cut out. I unhooked the plug from the back of the CD player and the ground wire was coming undone so I tried to pull out the little clip and put the wire back in with needle nose pliers and the plastic on the plug broke and the yellow constant and ground wires touched. I bought a new plug, and put red and yellow to positive, and black to negative on my battery, and the CD player works, but If I hook it up through the wiring in the dash it don't even come on. I checked the fuse for the radio and its good. Now the Question is PLEASE TELL ME WHAT IS WRONG!!!! Can you help? P.S.Would the cold create problems?

Answer
My suspicion is the voice coils are damaged.  When overpowered the contact connections on the cones melt and the connection become sporadic, often only when the voltage from the amplifier is high enough to restart the connection. It is quite a common occurrence with some designs.

If you have a VOM, check the dc resistance of the subwoofer (you must disconnect the wires coming from the amp). I think you will find this to be the problem.

You can get repairs on subs for this condition - sometimes you can resolder yourself and restore them....

Probably, the power amps are too strong for the woofer units.

Let me know if you need more,
Cleggsan