I was thinking about this a little bit, and no breakthrough "ah-ha" but
a couple thoughts that might jog someone else's memory, and a few things
to maybe try.

So, on your radio:
A) Power supply plugged in:
Headphone not plugged in - radio plays through speaker
Headphone plugged in - speaker off, radio plays through
headphones

B) Power supply unplugged (radio on bat):
*Headphone not plugged in - radio does not play through speaker
(the problem)*
Headphone plugged in - speaker off, radio plays through
headphones

Is this correct?

1) One thing to try, remove the battery, what happens? (Not sure why I
am suggesting this, assume it will play)

2) My thought is, the headphone jack is a 4 contact plug/receptical -
right, left, common, switch (receptacle only, senses barrel). The
"switch" is used to detect the presence of the headphones, and switch
the speaker off/headphones on (unless the headphone R/L/C are always
active). The switch is a normally open (NO) or closed (NC). Let's say
it's NO, you might think in B) that perhaps the switch is stuck closed.
However, with the power supply present (A) this contradicts this.

So, why would the designers have a different signal path and switching
for power than for battery? I would guess that there is an energy
efficiency to gain on battery that is not needed on line power. The
problem is to the best of my knowledge, there is no known radio
schematic. Personally I have not had one apart.

Maybe someone else has an idea. Until then I might suggest a couple
desperation things:

1) Use some deoxit, or even silicone spray on the headphone jack,
insert, twist, remove, repeat
2) If you feel like opening it up (there are instructions here
somewhere),see if you can find the wire on the jack that is "switch",
should be obvious. See if this changes start if you plug/unplug the
headphone
3) Do you have another radio to try swapping out ps, battery, etc? Not
sure if you mentioned...

Best I have for now. I have a radio with a battery here if there is
something you would like me to test
Jim


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