Well, I took the two screws out of the rear of the housing (next to the coil cable connector),
Pulled the electronics out the front, (one unit, two stacked boards, front panel, rear mount/cable connector)
Wires for the charger jack, toggle, and battery leads were short, but long enough to just let the electronics outside the housing.
What I found to be the problem,
The headphone jack was fine, its panel mounted in the twin board models.
The excess movement in the front panel was due to how the panel mounts to the circuit boards.
The front panel has two flat metal arms (legs) that are bent at a 90 degree bend. These two arms mount on each end of the panel and near the middle height wise and mount to the circuits boards. So, when you unplug the headphones the two arms FLEX and allow the front panel to teeter totter. So, I decided to do the unthinkable!
I put it back together, cleaned the lower inside corners of the housing, place a small bead of super glue jell in them (an inch up the sides and out across the bottom an inch) and held inward pressure on the front panel for about twenty minutes! then let it set overnight. It seems to be pretty solid now.
I have used it enough now that I'm pretty sure its running okay. So,
I'm not going to send it back,
I'm going to use it as it is until it dies (if it ever does).
My neighbor gave it to me, so I'm not going to try and sell it or get rid of it as long as it works!
Thank You All For Your Feedback!
Mark