Objective:

To allow proper airflow through the Time Capsule by enabling the fan and creating an airflow path.  Apple’s designed the fan to only operate once the device was severely overheating.  Further, there are not enough ventilation ports so that when the fan is enabled it is mostly recirculating hot air.  This solution permanently enables the fan, opens up an air port and voids the warranty (but see here for possible work-arounds).  Each step should take 1 or 2 minutes and does not require any specialized skills.

Step 1:

Remove rubber base by using pulling to off, the adhesive gives fairly easily.  Use a warm hair dryer to loosen adhesive if necessary.

Step 2:

Remove the 10 screws from metal base using a small phillips #1 tip.

Step 3:

Lift metal cover off being careful of the wires connecting the fan which is secured to the metal base.

Step 4:

Use needle nose pliers to gently remove the fan connector from the PCB board.

Step 5:

Used a pen or small screwdriver to gently push the rubber fan connector (furthest from the fan egress port) through the hole.  This frees the fan so that it flops on the two remaining secured points.

Step 6:

Use the template shown in picture on right, to mark a pattern for a whole that provides air to the fan’s ingress port.

Step 7:

The metal base is aluminum which is soft, so use a Dremel tool with a disk as shown to cut out the square air port for the fan.  Put a plastic ziplock bag around the dangling fan to protect fan from being contaminated with metal shavings (the last thing you want is the fan to blow around metal shavings inside the Time Capsule enclosure).  Move the fan out of the way to prevent cutting with Dremel tool - I used a desk with a hole in it as shown in picture.  Wipe up the metal shavings when done.

Step 8:

Reconnect the fans rubber grommet to the metal base by using a small screwdriver to work the rubber grommet through the hole.

Step 9:

Break the connection to the pin #3 wire of fan connector which can be done in two ways: 1) use scissors to cut wire at about half its length or 2) pull the pin out of the connector by using a sharp knife to slightly pry the plastic retention clip so the metal pin slides out and cover with tape to prevent internal electrical shorting once reassembled.  NOTE: pin #1 of the connector is labelled with an arrow, and pin #4 is labelled with ‘4’ so use this knowledge to find pin #3.  This step permanently turns the fan on (instead of it being off most of the time).

Step 10:

Reconnect the fan to PCB and reattach the baseplate with 10 screws.

Step 11:

Purchase some rubber feet that stand 1/4” to 1/2” tall and place at the four corners.  Laying down a couple pens will also work to provide clearance for airflow.  Don’t replace the rubber boot as that will cover the side vent hole and the new air port on the metal base which are useful for ventilation.  Also, if you ever need to attempt to return the Time Capsule to a store, you can replace the boot and cover up the workmanship you performed so the modification will likely go unnoticed - remember Apple stores are not allowed to disassemble the Time Capsule thus you have a pretty good chance of warranty coverage with this modification after replacing rubber boot.

Step 12:

Turn on and listen to the fan whir!  Lastly, you will be able to notice a major difference in temperatures by simply touching the outside surface of the Time Capsule - which makes the internal electronics much happier and they should now give you much more than 6-18 months of runtime.