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Microsoft Xbox Repair Manual

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See also: Instruction Manual , User Manual
WARNING!!! KEEP YOURSELF AND YOUR XBOX SAFE!
First of all if you have not opened your Xbox and you are having problems, think about using
your warranty if it's still covered. If you open the box it will invalidate your warranty.
CONTENTS
Page 1 of 87
page 2
page 3
page 4
page 6
page 7
page 8
page 9
page 11
page 13
page 20
page 24
page 29
page 30
page 33
page 36
page 42
page 49
page 54
page 57
page 59
page 76
page 78
page 82
page 84
page 85
page 86
page 87

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Summary of Contents for Microsoft Xbox

  • Page 1: Table Of Contents

    WARNING!!! KEEP YOURSELF AND YOUR XBOX SAFE! First of all if you have not opened your Xbox and you are having problems, think about using your warranty if it’s still covered. If you open the box it will invalidate your warranty.

  • Page 2: Warning!!! Keep Yourself And Your Xbox Safe

    Each ring represents any object, lets think of one of them as you and one of them as your Xbox, regardless of whether you are positive or negatively charged or both objects are either positive or both negative, the charge wants to equalize itself when the two objects meet causing a static spark.

  • Page 3: Dvd Repair

    DVD REPAIR If your Xbox is freezing during games or returning the dreaded Dirty Disc Error you have a DVD drive problem. If this all sounds like too much work you can always buy a replacement drive. First off, DO NOT BLOW CANNED AIR INTO THE DRIVE WITHOUT OPENING IT! This will almost certainly make things worse, you just assure that the dust will be redistributed evenly inside the drive and this includes a coating on the optics you are trying to clean.

  • Page 4: Determine The Manufacturer Of Your Xbox Dvd Drive

    Determine the manufacturer of your X-Box DVD drive Check Xbox DVD version without opening your Xbox. All DVD drives listed are compatible with all versions of X-Box Console 1.0-1.5 See “how to fix dirty disc errors” for more info. Hit eject on your X-Box and check out the tray. The Samsungs extra cut-outs are pretty obvious so that is easy to pick out.
  • Page 5 Updated some time ago, Phillips came out with a new drive that makes use of this hump. The laser is positioned vertically and the PCB is designed to allow the laser to pass through the board and make use of this empty area. Apparently, this was the design they intended to initially use when designing the X-Box DVD drive case and only implemented the changes to the internals recently.

  • Page 6: Determine Version Of Xbox

    DETERMINE VERSION OF X-BOX There are currently 7 versions of X-Box on the market today (10/24/04). These are referred to as 1.0, 1.1, 1.2, 1.3, 1.4, 1.5 and 1.6 • All original X-Box DVD drives work in all consoles regardless of version •...

  • Page 7: Xbox Power Supply Compatibility

    XBOX POWER SUPPLY COMPATIBILITY You can convert a 1.0/1.1 to a 1.2-1.5 by using this diagram 1.0-1.1 Consoles have power supplies with an AT style connector (one row of pins) 1.2-1.5 Consoles have power supplies that have an ATX style connector (two rows of pins)

  • Page 8: Power Supply Failure

    POWER SUPPLY FAILURE Power supply failure, the darn thing just won’t turn on. Usually proceeded by a popping sound right after attempting to turn on. In addition to the pop there is usually a hot smell and possibly faint smoke. Check out this link if you want to take a crack at repairing. I find this to be a waste of time since most often the fuse blew for a reason and if you do not fix the cause it will just blow again or swap it out.

  • Page 9: Convert A Psu 1.0/1.1 To A 1.2-1.5

    Use v1.0/v1.1 PSU for v1.2/1.3 console (v0.1) For those of you that have a blown & irreparable v1.2/1.3 X-Box power supply unit, you can now use a v1.0/v1.1 Xbox power supply unit to replace it. Lik-Sang offer a replacement v1.0/v1.1 (variable input) power supply.
  • Page 10 Join each wire, soldering each one, and insulate with heat shrink or insulation tape. Plug it in and go! Page 10 of 87...

  • Page 11: Xbox Version Detection

    LOCATION of Video Chip on motherboard (same on all versions) The video chip is located in the red square area Now check what brand of video chip you have (click picture that matches your Xbox) IMAGE1: 'Conexant' written on your video chip...
  • Page 12 IMAGE2: 'Focus' written on your video chip IMAGE3: 'xcalibur' + Xbox-logo on your video chip Select which picture matches with your Xbox: Your Xbox is like on image 1: see page 13 Your Xbox is like on image 2: see page 15...

  • Page 13: Xbox Version Detection - (Step1 Image1)

    LOCATION of the GPU on the motherboard (same on all versions) The GPU is located in the red area Now check if you have a FAN on the GPU (click picture that matches your Xbox) PICTURE1: There's a fan on the GPU...
  • Page 14 PICTURE2: There's no fan on the GPU Select which picture matches with your Xbox: Your Xbox is like on image 1: You have an Xbox v 1.0 Your Xbox is like on image 2: see page 17 Page 14 of 87...
  • Page 15 Use a multimeter to check if pin2 (red point on images) is connected with ground (screw plate for example). If you prefer you can also measure 3.3v (LPC pin 9) (Xbox must be ON) ... it's dead on a v1.5.
  • Page 16 LOCATION of one of the RAM chips The RAM chip is in the red area Now check which brand of RAM chips your Xbox has below PICTURE1: RAM made by Samsung (Samsung written on chip) PICTURE2: RAM made by Hynix (Hynix written on chip)
  • Page 17 Xbox Version Detection - (Step 2 Image2) Power connector (v1.0/v1.1 - v1.2/v1.3/v1.4/v1.5/v1.6) LOCATION of the power connector on the motherboard (same on all versions) The power connector is in the red area Now check how many rows of pins your power connector has...
  • Page 18 There's no perfect method to see the difference between a v1.2 and v1.3. We do know that all PAL Special Edition translucent green Xbox consoles (this is NOT the same as the NTSC Special Edition Halo Xbox) are still v1.2.
  • Page 19 XBOX VERSION DETECTION - V1.0 => You have a Xbox v 1.0 <= XBOX VERSION DETECTION - V1.1 => You have a Xbox v 1.1 <= XBOX VERSION DETECTION - V1.2 => You have a Xbox v 1.2 <= XBOX VERSION DETECTION - V1.3 =>...

  • Page 20: Cleaning Your Xbox Dvd Drive

    DVD from constant errors to less frequent glitching and pausing during movies and games. But I guess that is better than nothing. See disassembly procedure for details on how to get at your Xbox DVD drive! Necessary tools:...
  • Page 21 and two in the top, mid drive. Remove all four screws, the ones mid drive are a little hard to get out, screw grabber makes it easy, shaking the drive upside down works too. Remove the bottom tray first; flip the drive so the bottom is facing up.
  • Page 22 Now you have access to both the lens. and the mirror Blast the optics with canned air, and then continue on to the blast the rest of the DVD chassis trying to blow the remainder of the dust away from the optics. Using a Q-tip, clean the mirror and the lens with a high quality lens cleaner.
  • Page 23 You will probably need to pinch the top and bottom together and shift them back and fourth to get the screw holes to line up perfectly. Finish off with the rear screws, re-assemble the Xbox and hope you made things better rather than worse.

  • Page 24: Crack Open That Xbox

    CRACK OPEN THE XBOX Pause for a moment and ask yourself "Is there any chance I want to send it in to Microsoft for repairs?" Performing these steps will void your warranty and cause the "Opened Xbox" pricing strategy to go into effect; this means it will definitely be cheaper to buy a new one. Be careful in there, there is an exposed power supply with some big cans (capacitors) on it, they can hold electricity for years and are designed to dump completely in one shot.
  • Page 25 Once all six screws are removed, flip the box upright and grab the sides and shake it a little bit and the bottom should drop away from the cover. I find this is done most easily by putting the Xbox in my lap. Page 25 of 87...
  • Page 26 Step 4 - Drive removal, there are 3 screws total holding in both drives. First remove the one for the hard drive; it is located under the IDE cable. Two others are on either side of the front of the DVD drive. Once the screws are removed unplug the IDE cable to the Hard Drive and loosen the power cord from the track it sits in on the drive tray if you miss this step you won’t be able to remove the...
  • Page 27 Removing the power cord from the motherboard. Most sites tell you to use a pliers to remove the power plug as it is in there pretty good. I personally pull on the wires themselves, I risk yanking a wire out of the crimp in the socket, if I screw one up I am willing to repair it. Use your best judgment, the key is to grab half of the wires and pull evenly on all of them at a 45 degree angle, to raise one side of the plug first and then the other, it will not come out straight up.
  • Page 28 Step 6 - Eleven screws on the motherboard Remove them all and be careful not to scratch the surface of the board with the driver. Step 7 - Board removal You will need to disconnect the yellow wires coming from the fan, power and reset switches and also the connections to the USB game controller ports, the USB daughter board itself can be left in place or removed.

  • Page 29: Removing The Xbox Front Panel (Aka Bezel/Face Plate)

    Take your time and be careful. The goal is to remove the front panel without tearing the whole Xbox apart. You would need to do this if you were planning to paint it, install different color LED's in the power switch or just replace the power switch. This can be accomplished while the cover is off but the rest of the Xbox is assembled.

  • Page 30: Thomson Xbox Laser Installation

    The sides of the front panel clamp to the bottom of the Xbox with some good force so you have to pull twist and push harder than you might expect. Using the screw driver or other prying device attempt to move the front panel and the bottom plastic away from each other, moving the inside portion inward is easier than bending the front clamp outward but a little of each should get the job done.
  • Page 31 Next we remove the four screws circled in green above. These are in there tight, it is ESSENTIAL to use a good Phillips #0 screw driver and use plenty of down force to see that they do not strip out (if a cheap or well used screw driver is used with not enough down force it is likely to skip and hole out the inside of the screw where the driver grips, so use a good driver and be careful).
  • Page 32 Re-assembly is pretty much the same, remove the rail from the old laser, install it in the new one, and put it back in place making sure the gear is fitting into place. See that the bottom rail fits in place between the two "bumps"...

  • Page 33: Thompson Dvd Tray Removal And Realignment

    THOMPSON DVD TRAY REMOVAL AND REALIGNMENT For this tutorial we will be using a colorful pallet of made up words like thingy and nub... How to describe some of this better I do not know, well as always plenty of pictures to tell the story.
  • Page 34 When the actuator is to the left toward the circuit board the laser assembly is down and the hub that the DVD/CD's would reside on is below the tray. When it is below the tray as pictured below, slide the tray all the way out, there are two tabs circled in green that will stop the tray from coming all the way out, depress these and completely remove the tray.
  • Page 35 Another common point of failure is the little nub on the white actuator circled in green on the right, that little baby needs to fit into the trough on the bottom of the tray outlined in green in the next photo. Also note the teeth on the far left of the actuator, it looks like there are some missing right? No, that's normal.

  • Page 36: Phillips Xbox Dvd Drive Complete Disassembly

    PHILLIPS XBOX DVD DRIVE COMPLETE DISSASSEMBLY Tools: Phillips #1 Screwdriver T7 Torx Driver Remove four Screws circled in green Remove top cover All CD/DVD drives have some sort of mechanism to move the laser and hub up and down, the Phillips drive has one on the top, barely accessible at the front of the drive tray.
  • Page 37 To completely remove the tray, lift the catch on the right side of the drive. Now you should have a good view of the laser assembly note that on the Phillips drive there is a black gear rail that sometimes pops out of place and the drive begins showing Disc is Dirty or Damaged errors.
  • Page 38 Flip the drive over to remove the bottom cover. Note the black tabs that are circled, these often bind and make the tray difficult to remove. Push those in first then remove the tray. Now we should have a good view of the bottom PCB, note the screws circled in green, these must be removed only for total disassembly, and if you are installing a new laser it is not necessary to remove the screws.
  • Page 39 Now all the cables have been detached Take the end of the circuit board near the rear of the drive and flip it toward the front, this will reveal one more cord to detach. Page 39 of 87...
  • Page 40 Now the laser assembly is exposed from the bottom of the drive. As well as the top If you wanted to try cleaning the lens and mirror this would be as far as you need to go. Blast the optics with compressed air attempting to direct the dust away from the lens (top) and mirror (bottom) Use a clean Q-tip and lens cleaner to clean the optics, you want to achieve a streak free surface.
  • Page 41 Push them in the direction of the arrows and they will pop out and the laser assembly can be removed Now you should have a pile of parts that looks something like this Reassembly is the reverse. Install the laser by pushing the rubber dampeners into their sockets. Connect the circuit board to the white four wire connector on the chassis, lay the circuit board over the chassis and install the four black screws.

  • Page 42: Phillips Laser Installation

    If you are receiving Disc cannot be recognized it may be dirty or damaged errors on your Phillips DVD drive you can replace the laser to resolve the issue What you'll need: Phillips Xbox DVD drive with failing laser Replacement Laser Phillips #1, #0, #00...
  • Page 43 Removing the solder is best accomplished by wiping a clean 15Watt or other low temperature soldering iron across the pads, (be very careful!!!) the iron picks up the solder. Remove four Phillips #1 screws One of them is under the warranty void if seal damaged sticker Remove the top cover.
  • Page 44 The CD/DVD tray must now be extended to gain access to the laser. By sliding the actuator in the direction of the arrow below The tray moves about a 1/4 inch forward and can be opened the rest of the way just by pulling on it and it will slide freely.
  • Page 45 The rail is held in place by a small metal spring loaded tab. The metal is in the shape of a number seven (7) the small leg presses against the plastic and holds the rail from escaping; to remove we need to elevate the metal tab over the plastic so it can slide to the left.
  • Page 46 Getting the tab over the plastic is a two handed operation. I used two small regular precision screw drivers to lift and one to leverage to the side. In this photo you can see the tab is lifted over the plastic riser, and held in place by a screw driver, the rail can now be lifted up. In this photo the rail has been freed but the front is still attached, pulling the rail about a quarter inch back releases the front.
  • Page 47 Now that the gear and rail has been swapped over to the new laser it is time to re-install the laser and rail. Start by fitting the laser U shaped notch back into the lower rail in this photo. Next insert the top rail into the standoff at the top right in this picture.
  • Page 48 Using a precision screw driver, depress the tab so it is below the plastic, you may want to also replace the glue that holds the metal in its place. Reassemble and install in your Xbox! Page 48 of 87...

  • Page 49: Samsung Dvd Complete Disassembly

    SAMSUNG DVD COMPLETE DISASSEMBLY Tools Phillips #1 Begin with a Samsung Xbox DVD Drive flip over, remove four screws. The top and bottom covers come off easily To slide out the tray either use the emergency eject from the front of the drive or flip it over and slide this white thing in the direction of the arrow.
  • Page 50 Removing the DVD tray, two clips need to be depressed on either side of the front of the DVD to allow its removal If you are having tray eject issues the nub on the white thing circled below has most likely jumped out of the trough it fits in on the bottom of the tray, when reassembling the tray be sure this fits back into the trough on the bottom of the tray Removing the laser assembly, remove the two screws where the blue circle is in this photo...
  • Page 51 This is a view of the bottom of the drive and you can see the grommet on the right has been removed from its "C" shaped holder. The grommet on the left still needs to come out! With the laser loose I find this is a good time to remove the circuit board to gain easy access to the ribbon cables.
  • Page 52 Re-assembly - Install the laser assembly back into the chassis, put the shaft of a small screwdriver through the hole in the center of the rubber grommet and push it into place Note the large headed screws on the left in this picture have been installed Lay the PCB on top of the chassis and reconnect two ribbon cables Page 52 of 87...
  • Page 53 The PCB is held in place by two back plastic clips circled below, press the board into place Flip the drive into the upright position. On the top, install the ribbon cable that attaches to the laser. Note the position of the brown clip Once the ribbon cable is installed snap the brown clip into the locked position as shown below Put the top and bottom covers back on and you’re done Page 53 of 87...

  • Page 54: Thompson Potentiometer (Pot) Adjustment

    2mm standard screw driver (like for glasses) Torx T10 X-acto knife Digital Multimeter Start by disassembling your Xbox and removing the DVD drive Open your DVD drive Gain Access to the potentiometer by loosening the bottom circuit board enough so you can get a...
  • Page 55 For the purposes of this tutorial I have removed the ribbon cables to get better shots of the laser, this is not necessary for adjusting the pot Looking at the Pot we see 3 contacts. Position the drive so the single contact is on your left, the one to measure from on the right is the lower one.
  • Page 56 Touch points 1 and 3 with the probes, you use red or black with either it makes no difference. Get an initial reading, it should be over 1400 and not fluctuate. Scrape away the epoxy on the screw, not always an easy task and probably the most likely chance to irreparably damage your DVD.

  • Page 57: Ejecting Dvd Drive Manually (Emergency Eject)

    The tools, a paperclip! The bigger paperclips work best. Straighten it out as below. You will find a hole on all Xbox consoles at Arrow 1. If you stick your paperclip in that hole and it hits metal go on to point 2 (Phillips DVD drives) Both Thomson and Samsung DVD drives open via the hole at arrow 1.
  • Page 58 Once it is out far enough the tray can be pulled out easily, (never force it) Page 58 of 87...

  • Page 59: Explanation Of Error Codes

    Explanation of Error Codes Call Customer Service with No Error Number – see page 60 Description: When you attempt to boot, a 'you need service' message comes up, and has a LED style number on the top left hand corner. Here is what they mean. Disclaimer: This information is a believed to be correct, should be as close as it gets;...
  • Page 60 Special bios and utilities are necessary, some of these tools may not be legal since they may have been developed using Microsoft code so we are not able to recommend any nor post/point you in the direction of where they can be found.
  • Page 61 I don’t know myself. Another method of doing this is to put your PC next to the Xbox, use the Xbox to unlock the drive by powering it up, then swap the cable to the PC IDE cable and then allow your PC to detect it. If you have an Xbox with bad Hard Drive the process to swap gets a bit more complicated and there is no possibility of doing this without installing a modchip.
  • Page 62 XBOX Live, providing you have an unbanned EEPROM on a dead or working motherboard The smart thing to do is to always have a backed up copy of your Xbox’s EEPROM. It is a good practice to make backing up important data part of the modding process, specifically, your Xbox’s EEPROM information (done with Configmagic) and a backup of your C: drive (done with...
  • Page 63 That's all. You can now recover those memories, once thought lost, from your locked hard drive. Remember, when booting your XBOX only the locked hard drive you were trying to recover will boot. Any other hard drive will need to be unlocked to boot up.
  • Page 64 Xbox apps to easily unlock a drive with 1 button click. ConfigMagic can unlock harddrives, but also newer versions of EvolutionX dashboards and also all 4th generation modchip OS'. If your Xbox is broken or if for any other reason you want to unlock your Xbox HD on your PC this method...
  • Page 65 Simple way to format it in WinXP: Now boot to windows Enter "MMC" in RUN File-->Add/Remove Snap-in Click on ADD New window appears double click on Disk Management New window, click finish Click on OK Click on Disk Management (LOCAL) Then right click on disk 1 and select the first option Now right click on the right box next to the Disk 1 Box Then click on format, and format it the way you want it, select your partition letter and your ready...
  • Page 66 Extracting the HD password from an Xbox hard drive The Xbox harddrive uses a fairly old but relatively unused set of security commands to prevent easy access to it's built in drive. However, since the password system does not specify any form of challenge/reply system the password is transmitted in "clear"...
  • Page 67 The transfer of data to the drive cannot occur until BSY == 0. You will see (if you are watching the DIOR line) that the Xbox is polling that register waiting for the bit to clear. When it does the Xbox will begin transferring the data bytes to the drive.
  • Page 68 DIOW line changes, but should be able to see all of the actual data bus changes. If you decide to try this, verify it works on some other drive before using your Xbox drive, as I have no idea what kinds of problems might come up if it fails.
  • Page 69 Error Code 21. When Error Code 21 comes up power off the Xbox, unplug the Xbox 1's hard drive and put it back into Xbox 1. Reconnect all the cable to Xbox 1's hard drive and boot it. It should boot fine. Now power off and put both Xboxes back together.
  • Page 70 More importantly you are able to use this to install Linux on an Xbox, through the use of an altered bios you will be able to link your Xbox through a network connection and upload files as necessary.
  • Page 71 Notice how the solder around R71R covers two traces and the splash links a third. If you look closely you will see similar situations on several of the other soldier points. If you have never used a soldering iron on electronics before, an Xbox motherboard is a bad place to learn. Try on an old board first! Error 7 - kernel This is a hard drive error.
  • Page 72 So I placed a regular hd drive in it, and it gave error 16. I was expecting 05, but since the drive did not contain any Xbox partitions it seems logical. So I put in a game cd and then I did get error 5.
  • Page 73 Flashing Red and Orange (Amber) Video display problem, check cord. Also try switching to another video mode by changing the cable. I currently have an Xbox that displays this error when connected to the standard composite video cable but boots fine when connected to a RF adapter cord.
  • Page 74 LED light turns steady green just like it would look if it were working fine. This fix works only on 1.0 and 1.1 consoles since the first Xbox mother boards included a 1MB bios chip, this chip is divided into 4 256K banks, the steps described below are used to force the Xbox to use one of the other three banks since the primary bank has become corrupted.
  • Page 75 Quick install Download the patched Cromwell image here: http//arisme.free.fr/Xbox/Reflash/Cromwell-patched.zip Download the EEPROM patcher here: http/arisme.free.fr/Xbox/Reflash/addeeprom.zip Unzip the image and the patcher, put both in the same directory with your EEPROM image, and patch the Cromwell image with your EEPROM: addEeprom cromwell-patched.bin eeprom.bin Program your mod with cromwell-patched.bin...

  • Page 76: Repairing Traces And Lifted Pads

    Repairing Traces and Lifted Pads Here is a photo of an Xbox motherboard that has a failed mod attempt. Prior to fixing the traces the box would attempt to boot three times and then go to the flashing red and green led. The orange line in the upper center is where a conductive pen was used to attempt to re-connect a lifted trace.
  • Page 77 Using a 15-20 Watt soldering iron tin the points and the ends of the wires with solder. All you need to do is make contact, don't focus on getting a large amount of solder, a wire that stays in place is all you need there will never be any stress on the wires and it is not a race, take your time. Use an X-Acto knife to scrape off any green board material away from the solder points.

  • Page 78: Original Xbox Controller Repair

    Original Xbox Controller Repair Opening a Controller - Don't Suffer With Sticky Buttons!! By far the easiest fix, may as well spend the 30 minutes it takes to clean them up. Nothing worse than dieing because of a missed shot or jump! So for those of you that need a little encouragement here we go.
  • Page 79 You can now safely remove all the buttons and rubber cups they sit in. I gave all the buttons and D-pad a nice bath in warm soapy water. If the board has become drenched with your favorite soda or whatever use some mild soapy water on a rag to clean it up, stay away from window cleaner and other harsh cleaners.
  • Page 80 Alright, now we are ready to take the bottom and lower it on top of the buttons and top cover. Put the screws back where they were and you are done! Fix your broken Xbox controller cord. Cut away the damaged portion of cord and strip back the insulation a couple of inches.
  • Page 81 Xbox Controller Cord Replacement AKA Opening an Xbox S-Type Controller Begin with a controller with known physical damage to the cord. Or one you suspect has a bad cord.

  • Page 82: Xbox Locks Up / Flashing Red/Orange

    Keep in mind that in game lockups can also be caused by DVD issues but if can stick your Xbox in a cold place and notice that this gives you stable play time read on.
  • Page 83 Once you have thoroughly cleaned the motherboard using compressed air, remove the backing from the heat sink and place it squarely on top of the chip, continue to put firm (within reason) pressure on it for two minutes. Now to take the last step to improve cooling as much as possible we will replace the standard power source for the fan with a higher voltage one to make the fan run faster.

  • Page 84: Xbox Will Not Power On

    1.6 Xbox will not power on I found this to be the case after working on a failed mod board. I was in the process of repairing traces and booted it many times without issue then suddenly without warning the box would suddenly not respond to power or eject buttons.

  • Page 85: Fan Replacement -- Alternate Power Source For Fan

    PC case fans and may have one lying around. Insert it inline to the cord going to the hard drive and your all set! Whenever the Xbox is on so is the fan just as it is with the motherboard power header. This is also known as the 12V fan mod.

  • Page 86: The Short Xbox Diagnosis Answer List

    The Short Xbox Diagnosis Answer List Here is the short list of Problems and Solutions to fix broken Xbox consoles, if you are looking for an elegant answer keep reading the forums a few exist. If you want to just swap out the broken component and get up and running here is a list of every error and what is suggested to replace.

  • Page 87: Dvd Drive Failure

    3. Fix existing DVD drive. 4. If your original Xbox DVD drive is dead, completely, no life at all, this may help you. There are 2 small fuses on the drive PCB on the opposite side to the BA chips (look elsewhere to see how to get to them) they are brown rectangles with the markings "MP200"...

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