Hi
I did not make this mod yet, but I can say it will work with the charger.
Anyway the diode is there and its function is to reduce 0,7 Volts from the 5 Volts provided by the USB port.
With this you get 4.3 Volts on the headset, much better than 5, yet you will have 1.3 to 1.8 Volts of difference. If you can measure the current that passes the diode we can calculate the value of the resistor to get the remaining voltage on the resistor, else you can use two more diodes to remove 1.4 Volts from the headset.
Just like this ------|›|----------|›|-----------|›|----------
Voltage 5V 4.3V 3.5V 2.8V
Hope this will help you out to solve the over voltage issue
Best regards
JO