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I am wondering if this issue could be related to the issues that the Palm Treo line has regarding listening to music through headphones vs. the internal speaker. You see, the Treo headphone/handsfree jack has a built-in sensor to detect whether headphones are plugged in or not. It senses this by the amount of resistance on the line. If there is little to no resistance, the Treo plays music through the internal speaker. If there is resistance on the line, such as that provided by headphones, then it diverts the audio to the jack and plays through the headphones.
Many users solved this problem by adding a radioshack in-line volume adjuster and turning it down to about 80% of max volume. The theory is that this provided enough resistance to trick the sensor into always sending audio to the jack, not the speaker. I wonder if this would work for the Mini?
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