How To Fix Broken Headphone Wire Without Soldering. Do not take the risk of. Lighten the wire at one end with a torch for just a second.

You can still fix your broken headphone wires with simpler tools. Make your broken useless earphones working nice. Cut above the frayed portion of the cable using wire cutters.
Use caution to avoid cutting too far into the wire.
Focus On Your Headphones. Use Heat Shrink Tubing. Another annoying thing about soldering is that it takes a while to heat up solder a joint and then hopefully without getting burned hang the iron back on a stand or hook. Look for debris on the meshes in each earbud.
