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Welcome to Pocket PC Thoughts. A few things you should try before cracking it open:
(1) Try plugging the headphones in and out of the socket about 10-20 times continuously. On very rare occasions, the speaker/headphone switch within the device becomes stuck, so it requires something as simple as the aforementioned suggestion to make it work again.
(2) If that doesn't work, try a soft-reset. And in dire circumstances, you may also want to try a hard-reset, but ensure you backup first.
(3) If none of that works, it's probably a hardware issue (as you initially suggested). It's been a while since I bought an HP Pocket PC, so I'm not sure if their warranty policies have changed. Check to see if your device is governed by an international warranty. If so, I'm sure it's very easy to have it shipped to the nearest service centre for warranty repair/replacement.
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