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Comments
What resistance value is the pot?
It is possible that repeated heating with a soldering iron has damaged the innards of the pot.
Pot is B500K
If all else fails I'll replace the pot.
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I've replaced the pot with a new A500K. Will check out the jack wiring later.
A common failure point is the rivet where the ground terminal is attached to the trackboard, often strained when the terminal is bent back to solder it to the casing. Squeezing the rivet hard with some fine-nose pliers will often fix it.
On this type of jack, if it's not being used for stereo or an active circuit battery switch, always connect *both* the ring and ground connections to ground - this greatly increases the reliability of these unreliable jacks by almost guaranteeing that the ground contact can't fail... leaving only the tip contact as the weak point.
"Take these three items, some WD-40, a vise grip, and a roll of duct tape. Any man worth his salt can fix almost any problem with this stuff alone." - Walt Kowalski
"Only two things are infinite - the universe, and human stupidity. And I'm not sure about the universe." - Albert Einstein
But basically, you can always connect unused contacts to whatever they’re in parallel with to gain a ‘backup’ connection in case the first one gets dirty/corroded/stressed and isn’t making a reliable contact.
"Take these three items, some WD-40, a vise grip, and a roll of duct tape. Any man worth his salt can fix almost any problem with this stuff alone." - Walt Kowalski
"Only two things are infinite - the universe, and human stupidity. And I'm not sure about the universe." - Albert Einstein