Originally posted by Tatume I just measured the barrel diameter of the jack. It is 0.098", so I presume the nominal diameter is 0.100". I would have thought that being undersized only 0.002" would not have been a problem,
Actually I think the specification is written in millimeters and that is a 2.5mm jack which works out to about 3/32" not the 1/8" I quoted above. And 3/32" is .09375". I assume a certain amount of tolerance for fit. I just measured mine out of curiosity and the male barrel measured exactly 2.5mm.
I have come across a lot of those jacks where they just are not quite up to spec and cause problems, just cheaply made and no quality control. Anyway glad you found an answer.