Originally Posted by ka1

Hi,
Hopefully this may help someone.

I thought my Treo was hosed, as it would not let me unlock it when I turned it on. Eventually, by repeatedly rebooting and trying various things, I found out the problem was my "p" key was stuck. It was sending a long stream of p's whenever I tried to do anything (or nothing).

Sure enough, when I tried pressing the P key, it would not make a "click" like the other keys did.

So, with little to lose (sound issues, old Treo, less than a year on my contract, previously voided warrenty), my attempt to fix it, which sorta worked, included:

1. take out all loose parts (battery cover, SD card, battery, stylus)
2. remove the 6 screws with a #5? torx wrench (careful-this will void your warrentee).
3. opening the case. The front and back are connected by a thin tape-like connector.
4. Removing the front completely by opening the clasp that holds the tape-like strand of wires in its socket. This looked alot like my old Handspring Visor. You can just life up on the clasp (the "mouth" is facing outward, along the long side).
5. The keypad is this white tablet, held in place by tiny screws (philips head). I removed both, and was able to take out the tablet. The keys themselves stayed attached to the front. The back of each key just had a plastic pin, and the keys were all loosely connected, with each set of 4 pivoting against each other.
6. The key tablet was mostly a peice of white plastic on the bottom, a few milimeters thick. The top was covered in some sort of foil. You could see little small circles drawn on the foil top, where each key-pin hits. There were rectangular holes in the foil, roughly every-other key. Around the little drawn circles you could see a raised "hump". You can click on each circle and feel it invert, then pop back out. Feeling really lucky, I peeled back the edge of the foil where the P circle was located. I saw silvery, saucer-like connectors, one for each key. The outer edges seemed to line up with the edge of a target-like design on the other side, so that when you press in on the saucer, the outer makes contact with the ring around the bulls-eye, and the center then touches the center circle of the bulls-eye. I gently tried to push the center of the P saucer so that it was back to the proper inverted shape.
7. I then pushed the foil back down, covering the switches, and put it all back together.
8. I turned on my Treo, and it now seems to work. Not perfectly (the P is now TOO hard to press, but it does click, and no more random streams of P).

Hope this helps someone.