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d_light, kindly watch the language, this is a G rated site. As to the questions you asked, the audio processing in the Axim is really pretty good. Most users have reported excellent audio when using good quality headphones through the audio socket. Opening the case should be considered the same as hard reset. Even if you could leave the BUB in and/or external power attached, you would/should remove power to do the surgery to replace the speaker itself. It's not prudent to work on electronic devices with the power on. THe danger is not to you, because the voltages and current in these little devices is low. The danger is that because of the low voltages and currents involved it doesn't take much to "fry" one of these components and end up with a brand new speaker installed in a paperweight.
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