Anyone Modify current Nuvi with 3.5mm phone jack?

Perhaps you could try a bluetooth model and use a bluetooth headset. That may be an all around easier solution.

I don't know what your price range is to be considered affordable, but you can usually get great deals on refurbished units. I am still very happy with my 2450 (not a bluetooth model, but the 2460 is.)

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Look for some of the older models that have earphone jacks like the 6xx, 7xx, etc series. eBay would be a good place to start looking. I don't know what you would have to do to update the map(s) but it should be possible.

Many states prohibit the use of headsets while driving:
http://drivinglaws.aaa.com/laws/headsets/

This is likely one of the reasons Garmin does not provide an audio output jack on their newer Nuvi’s.

The Zumo series is primarily designed for motorcycle use where the headset laws differ. If you are planning to use a Nuvi on a motorcycle, then Jfossy’s suggestion of trying a Bluetooth headset or Jackj180’s idea of getting an older GPSr with an audio output jack may be worth trying. There is a previous post on the motorcycle mount subject which may be of interest.
http://www.poi-factory.com/node/27527

I’ve cracked the case of a few Nuvi’s in the past and there is very little free space inside for something as large as an audio jack for which the unit wasn’t designed. Connecting a pair of wires to the speaker terminals is a possibility assuming you can get access. The wires can then run outside the case and attach to an external jack. Not the neatest solution but it’s a possibility.

If you have a smartphone, another option might be Garmin’s Viago navigation software. You can then use the phone as a GPS and it’s Bluetooth or audio output jack to connect your headset.

I too was thinking of mounting the jack externally and drill a small hole in the case to put the wires through. Then seal the hole with silicon to prevent moisture getting in. Making a housing for the jack may be challenging as well as securing it to the case.

I don't believe what you suggested by "connecting a pair of wires to the speaker terminals is a possibility" is a viable solution.
I may be wrong, but I believe by doing so it would still send the sound to the internal speaker even with the headset plugged in. This would reduce the sound level to both the internal speaker and headset. I think it needs to be wired in a manner that when the headset is plugged into the jack it bypasses the internal speaker.

Maybe somebody with better electrical knowledge can offer better advice.

A typical headphone jack will have an automatic bypass switch for the internal speaker when earphones are plugged in. The voltage level to drive a speaker might be too high for earphones, but that could be compensated for with a little experimentation by adding a resistor to the earphone circuit.

Having changed batteries in both of my Nuvi's, I can confirm that there is extremely little room inside for adding anything. It's possible to do what the OP wants, but he would probably have to have the jack hanging out loose, connected via wires to the inside.

Adding a resistor, a bypass switch, and having the Nuvi look like a Rube Goldberg production is not worth the effort in my opinion. Smarter to replace the Nuvi with a 7XX or 8XX series on Ebay.

@rkruz,
I am just wondering.. with all the comments here, what are you deciding to do?

Viago is another option if the OP has a smart phone. It is relatively inexpensive.

I keep my old nüvi 760 going. It not only has an audio out jack it also plays mp3 and aud files. I listen to audio books from audible.com while driving and play them through the car stereo. It pauses the book when giving directions and then picks up a second or so before the pause so nothing is lost. Since it uses the audible player I can also make bookmarks and move forward or backward incrementally. I love it.

@rkruz
You already own the 855 model that has the external jack. I would than venture to guess you just want a newer model with more features, thus your question.

NO newer units have external jacks, and after reading the replies you can see there are no practical solutions other than having an unsightly GPS and voiding the warranty on a new unit since it was tampered with.

Some have recommended using a Bluetooth headset, but the Nuvi only pairs with phones and is not equipped with the ability to pair to a headset. Nuvi can pair with your phone and will provide hands free use sending sound through the GPS speaker. Sorry.

Best bet is a used Nuvi 765T which has both audio out and mic in ports as well as A2DP stereo Bluetooth, or just get the Zumo. Well worth it IMO. Other alternatives are to buy discontinued Streetpilot 27xx or 28xx, or the Zumo 550 which is now much lower in price since the 590LM has come out.

I have a late-model (2014) nüvi® 2699LMTHD and would really like to modify it so that I can feed the audio into my car's aux audio input jack. Once the warranty expires I will take it apart and see if that is practical (even if it requires an outboard connector).

I have an old Nuvi 255 and I'm thinking of trying to add an external jack/cord to connect audio to my motorcycle's aux in

I personally did not do it, but I had a company install a 3.5 jack so I could add a bluetooth transmitter for my Harley. These people did it, charged 60 bucks, plus shipping. The Nuvi 255 works great.

http://www.palmdr.com/

Hi 2Bit

I opned mine and will take pics to post shortly. Can you post a pic of your unit ? Where did they put the plug - there isn't much room in there

I really don't understand why the new units aren't designed to play through the car stereo. It seems really idiotic to me. It was a wonderful feature.

I remember when the FM transmitter was on the nuvi units...

The jack wire came out of the back on the left side of the unit by the sd card slot.

Don't think we can add 3.5mm jack.

Rube Goldberg called, said he wanted his GPS back.

Modified a Nuvi 40 by soldering on wires to the existing speaker. Even at 10% volume with the internal speaker connected it's loud enough for shit quality in-ear headphones. I used 60-second epoxy and hot glue to stick a 1.5mm jack to 3.5mm. I ride a motorbike and need turn by turn directions without looking at the screen, although i'm working on some kind of pip-boy 3000 arm-GPS.

I'll just leave this here.
http://imgur.com/a/F0VEL

Great post and pics DaveUK, thank you

I opened my 255 and there is little to no room inside as others have mentioned - Guess I'll try the external route

Steve

Thanks for all the advise. electrically it would be a simple matter to add a swithing phone jack to the internal speaker wires with appropriate impedance. Mechanically it would difficult to secure the jack for repeated use.
The best choice for me is buy additional 855s or another older model Nuvi with phone jack. At $35-65 on Ebay I can 10-20 of them vs the outrageous price for a Zumo. I can buy a memory chip map upgrade for $25. This application is to be used with earbuds inside a motorcycle helmet.

@rkruz ... I realize you are familiar with the nuvi 855 since you already own one. But one downside to buying an old 8x5 nuvi is that it is no longer possible to buy replacement batteries for them. I have spent hours online searching for a reliable vendor for the 855 battery at a reasonable price and have had no luck finding one. I suspect the battery manufacturers are no longer making them. So even if you find one, it is probably used or old stock that has been sitting on the shelf for years. Some sources that claim to have the battery in stock are asking ridiculous prices.

The 855 will not operate with a dead battery (even when plugged in), but it will run with the battery removed if it is correctly powered through the cradle or USB.