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Introduction

Replace a damaged rubber control button cover.

What you need

Accessing the internals of the 4th generation Shuffle is extremely difficult, as the rear panel is both glued to the front case and secured by metal retaining clips. It is highly unlikely that you will be able to remove the rear panel without inflicting cosmetic and/or structural damage.
Before proceeding, be sure your Shuffle is switched off.

Use a heat gun, hairdryer, iOpener, etc. to heat the back of the Shuffle until it's slightly too hot to the touch.
If using a heat gun, only apply heat for a few seconds at a time. Check the temperature of the metal - if it gets too hot to handle, let it cool.

Use a combination of iPod opening tools and metal spudgers to pry the rear panel away from the Shuffle by the seam nearest the ON/OFF switch.
There are no clips on the top and bottom of the rear panel. With the Apple logo upright and facing you, all the clips are to the left and right.
If you use a metal spudger, you will scratch the housing.
You can try to pull on the rear panel by the clip. If you use too much force, you will bend the rear panel. If it feels stuck, stop and heat the glue to soften it.

Remove the rear panel from the Shuffle.
There may be a piece of black rubber covering the logic board, or it may come out with the rear panel. This piece is part of a rubber seal that goes around the edges of the rear panel and covers the controls from the inside.

If present, remove the thin black moisture seal covering the Shuffle's internals.
Remove the single 2.1 mm Phillips screw securing the logic board to the front case.

Tool used on this step:

Tweezers

$4.99

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Use the edge of an iPod opening tool to flip up the retaining flap on the control button cable ZIF socket.
Be sure you are prying up on the hinged retaining flap, not the socket itself.
Use a pair of tweezers to gently pull the control button ribbon cable out of its socket.

Use an iPod opening tool to gently pry the battery off the adhesive securing it to the front case.
Lift the battery out of the front case, being sure not to strain its delicate leads.

Insert the tip of a metal probe into the hole molded into the logic board retainer nearest the logic board.
Pry the retainer first away from the front of the front case, then pull it away from the side of the front case.
Remove the logic board retainer from the Shuffle.

Use the edge of an iPod opening tool to push the headphone jack down toward the center of the Shuffle.

Continue pushing the logic board down away from the top edge of the Shuffle.
Pull the logic board out of the front case by the side nearest the ON/OFF button and gently maneuver the headphone jack out of its recess in the front case.
Remove the logic board assembly from the Shuffle.

Use an iPod opening tool to pull the control button plate out of the front case.
Remove the control buttons from the Shuffle.

Push the rubber control button cover out of the front case.
When reinstalling the control button cover, be sure it is properly aligned and that its top and bottom edges are seated in the grooves cut into the front case.