Why is the headphone jack on the outside of the OtterBox for iPod cases so tight?
When designing the OtterBox for iPod cases we decided to use a jack that would not allow for your headphones to pull out accidentally during use. If the headphone jack on your case is really tight, trying inserting and removing the headphone plug 5-10 times. This should loosen up the jack to where it is still secure, but not too tight.