If the screen cracks on an out-of-warranty iPod Touch or iPhone, you either need to pay for it to be repaired, purchase a new one, or attempt to make the repair yourself. In this case, we chose the latter option and purchased replacement glass and some iPod opening tools from iFixit.
After prying off the iPod's chrome backing, the second hurdle was carefully pulling the rechargeable battery pack away from the other components--a task not helped by the considerable amount of glue used to affix the battery.
The battery was small potatoes compared to the removal of the iPod Touch logic board, which aside from being the fragile heart of the entire system, was held in place with both glue and four miniature screws.
Here's a shot of the iPod Touch LCD, separated from the rest of the components. Fortunately, the LCD was unharmed from the drop that cracked the exterior glass.
After using a hair dryer to heat the adhesive that held the broken glass in place, I removed the old glass and prepared the metal rim to receive the replacement glass. Once the glass was in place, a hair dryer was used again to bond the leftover adhesive to the new glass.
Once the new glass cooled down from the hair dryer treatment, I reversed all the steps, reassembled the iPod, and breathed a sigh of relief as I watched the screen light up.
