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Microsoft XBOX CONTROLLER Repair Instructions

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XBOX CONTROLLER SAFETY
& REPAIR INSTRUCTIONS

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Summary of Contents for Microsoft XBOX CONTROLLER

  • Page 1 XBOX CONTROLLER SAFETY & REPAIR INSTRUCTIONS...
  • Page 2 To the fullest extent permissible by law, Microsoft shall not be liable for damages of any kind arising from the use of information, content, materials, or product made available in or in conjunction with this Guide, including but not limited to direct, indirect, incidental, consequential, and/or punitive damages unless otherwise specified in writing.
  • Page 3 Introduction This Service Guide (Guide) provides instructions for repairing Microsoft Xbox devices and accessories using genuine Microsoft parts. It is intended for technically inclined individuals with the knowledge, experience, and tools required to repair Microsoft devices. IMPORTANT: Read this Guide in its entirety before starting any repairs. If at any point you are unsure or uncomfortable about performing the repairs, as detailed in this Guide, DO NOT proceed.
  • Page 4 DO NOT proceed. Refer to Actions to Take under Handling Used, Damaged or Defective Lithium-Ion Batteries in this Guidebook or contact Microsoft directly for proper device disposition.
  • Page 5 For additional product safety information relevant to Microsoft Xbox devices or accessories, see aka.ms/xbox-safety. Repair-Specific Precautions and Warnings Before opening a device, ensure it is powered off and disconnected from its power source for at least 30 seconds. Disconnect the device charger or power cord from mains power.
  • Page 6 For optimum compatibility, performance, and product safety, we recommend using • genuine Microsoft replacement parts. Use of non-Microsoft (non-genuine), incompatible, reused, or modified batteries; improper battery installation; improper handling or storage of batteries; and/or failure to follow the instructions in this Guide could cause battery...
  • Page 7 Exercise caution when using sharp tools near the battery to avoid impacting ▪ or poking the battery. Don’t leave loose screws or small parts inside the device. ▪ Avoid using tools that conduct electricity. ▪ Do not drop or throw a lithium-ion battery. ▪...
  • Page 8 Follow the safety instructions provided below: Battery replacement may be performed by individuals with the knowledge and skills • needed to complete complex electronic repairs. All repairs must follow Microsoft procedure. See https://aka.ms/xbox-safety for important • information. Risk of fire or burning.
  • Page 9 Report Battery Thermal Events to Microsoft A thermal event is a rapid chemical chain reaction that can occur inside a battery cell. During a thermal event, the energy stored inside the battery is released suddenly, resulting in heating and/or smoke and, in some instances, fire or flame.
  • Page 10 Defective Lithium-Ion Batteries (page 9) for additional information. Stop Repair and Contact Microsoft If any Microsoft device visually exhibits any of the following symptoms, cease all further repair efforts and contact Microsoft Xbox Customer Support to report and obtain next steps: Any burned or melted components, traces, or plastic parts on the outside of the device, or •...
  • Page 11 Clear photographs depicting the symptoms observed. ▪ Environmental Compliance Requirements All waste electrical and electronic equipment (WEEE), waste electronic components, waste batteries, and electronic waste residuals must be managed according to applicable laws and regulations. Please do not dispose of waste lithium-ion batteries in your household garbage can or recycling bin as they may ignite if improperly managed.
  • Page 12 ELITE SERIES 2 XBOX CONTROLLER REPAIR...

  • Page 13: Table Of Contents

    Table of Contents Top Case Replacement & Installation Instructions ……………….………………… pg. 14 Mid-Frame Separation Process ……………….……………………………………………… pg. 20 Bumper Replacement Process ……………….……………..………………………………… pg. 26 Battery Replacement Process ……………….………………………………………………… pg. 31 Mainboard Replacement Process ……………….………………………………..………… pg. 39 I/O Board Replacement Process ……………….………………………………….………… pg. 55 Button Replacement Process ……………….……………………………………….…………...

  • Page 14: Top Case Replacement & Installation Instructions

    Top Case Replacement & Installation Instructions...
  • Page 15 Top Case Replacement & Installation Instructions Required Tools and Components Tools Anti-static wrist strap (1 MOhm resistance) • Soft ESD (electrostatic discharge) safe mat • Microfiber / lint free cloth • Safety glasses • Plastic pry tool (spudger) • Dispenser bottle with Isopropyl alcohol (use 91% or greater) •...
  • Page 16 Procedure – Removing the Top Case NOTE: Remove all removable paddles, D-pad, and Thumb stick caps before starting disassembly. NOTE: If any plastic snaps are damaged during removal of the Top Case, the Top Case must be replaced. 1. Separate Top Case Using a plastic pry tool, insert the edge between the parting line at the top of the controller, between the top and bottom cases.
  • Page 17 2. Remove Top Case After releasing all snaps, work your way around the device, slowly pulling the Top Case off the device. Note that the two PSA strips on the underside of the Top Case will cause some resistance when removing the part. Make sure you take your time to prevent damage and pull away to reduce any injury.
  • Page 18 3. Remove PSA If you’re reusing the Top Case, we recommend peeling off the PSA off with a pair of tweezers. Clean any residue with isopropyl alcohol and a cotton swab to ensure a clean surface for new application. Procedure – Installation (Top Case, Xbox Elite Series 2 Controller) 1.

  • Page 20: Mid-Frame Separation Process

    Mid-Frame Separation Process...
  • Page 21 Mid-Frame Separation Process Required Tools and Components Tools TR8 (Torx Security) driver • Anti-static wrist strap (1 MOhm resistance) • Soft ESD safe mat • Microfiber / lint free cloth • Plastic pry tool (spudger) • Plastic tweezers • Pliers (Elite Only) •...
  • Page 22 2. Separate Mid-Frame Carefully lift out the mid-frame, separating it from the back case.
  • Page 23 Procedure – Installation (Mid-frame) 1. Install Mid-Frame Ensure the trigger stops on the back case are set to the upper-most (full stroke) position. Pull the triggers halfway and lower the mid-frame onto the back case, ensuring no wires are pinched between the mid-frame and the back case. Verify that LT and RT function normally before proceeding.
  • Page 24 2. Install Screws Using a TR8 (Torx Security) driver, install the 6 screws securing the back case to the mid- frame. Turn each screw until finger tight, then turn another 1/8 turn (45-degrees), or until fully fastened.
  • Page 25 3. Install Top Case Install the top case as detailed in the Procedure – Installation (Top Case) for the appropriate device. (page 14)

  • Page 26: Bumper Replacement Process

    Bumper Replacement Process...
  • Page 27 Bumper Replacement Process Preliminary Requirements Required Tools and Components Tools Anti-static wrist strap (1 MOhm resistance) • Soft ESD (electrostatic discharge) safe mat • Microfiber / lint free cloth • Plastic pry tool (spudger) • Plastic tweezers • Components Bumper (Refer to Illustrated Service Parts List) •...
  • Page 28 Procedure – Removal (Bumper) 1. Remove Top Cap Using a plastic pry tool, pry the top cap tabs up and off the locking posts on the mid- frame. Then slowly twist the cap off the top of the mid-frame. 2. Unhook Bumper Clips Using the pointed end of a plastic pry tool, unhook the edge clips on the right and left of the bumper.
  • Page 29 3. Remove Bumper Gently lift the bumper off the controller. Procedure – Installation 1. Install Bumper Cap Gently place the bumper on the controller, making sure that the inner posts slot into the controller, not over the mid-frame. 2. Hook Bumper Clips Using a plastic pry tool, hook the left and right edge clips of the bumper to the mid-frame.
  • Page 30 3. Install Top cap Hook the bottom of the top cap to the bottom of the mid-frame and rotate into place. Using a plastic pry tool, pry the top cap tabs up and onto the locking posts on the mid- frame.

  • Page 31: Battery Replacement Process

    Battery Replacement Process...
  • Page 32 Battery Replacement Process Preliminary Requirements Required Tools and Components Tools T6 (Torx) driver • Anti-static wrist strap (1 MOhm resistance) • Soft ESD safe mat • Microfiber / lint free cloth • Gloves • Safety glasses • Bucket of sand (1 gallon) •...
  • Page 33 Remove Mid-Frame Remove the mid-frame as detailed in the Procedure – Removal (Mid-Frame) (page 20) Procedure – Removal (Battery) REMINDER: Please read the Battery Safety warnings located in the Safety Instructions at the beginning prior to getting started. 1. Remove Battery Lid Use a T6 (Torx) driver to remove the 4 screws from the battery lid.
  • Page 34 2. Remove Contact Pins Using your fingers, remove the battery contact pins from the back cover. 3. Lift out the battery Gently lift the battery out of the well by pressing on the side of the battery and lifting. Set battery on a clean, flat surface.
  • Page 35 Procedure – Installation (Battery) IMPORTANT: Do not reuse the old battery when performing repairs. Always use a new battery when the old battery has been removed from the device. Pre-Installation Device Inspection Check the chassis for any loose articles that may be present. Verify all removed screws are accounted for and have not been misplaced inside the •...
  • Page 36 If battery is dented or punctured during installation, discard the battery, and use a new battery pack. Only handle battery by plastic enclosure. There is no plastic frame on the top of the battery to protect the battery cells from damage. Bending, twisting, or impacting battery may damage the battery, damage the device, and/or result in severe personal injury or property damage.
  • Page 37 2. Install Battery Lid Place battery lid over battery. Use a T6 (Torx) driver to install the 4 screws in the battery lid. Turn screws until finger tight then tighten by an additional 1/8 turn (45-degrees) or until fully fastened.
  • Page 38 3. Install Mid-Frame Install the mid-frame as detailed in the Procedure – Installation (Mid-frame) (page 20) 4. Install Top Case Install the top case as detailed in the Procedure – Installation (Top Case) for the appropriate device. (page 14) 5. New Battery Charging New batteries are shipped and stored at low states of charge in compliance with shipping regulations.

  • Page 39: Mainboard Replacement Process

    Mainboard Replacement Process...
  • Page 40 Mainboard Replacement Process Preliminary Requirements Required Tools and Components Tools T6 (Torx) driver • Anti-static wrist strap (1 MOhm resistance) • Soft ESD safe mat • Microfiber / lint free cloth • Cotton swab • Plastic pry tool (spudger) • Plastic tweezers •...
  • Page 41 Remove Bumper Remove the bumper as detailed in the Procedure – Removal (Bumper) (page 26) Procedure – Removal (Mainboard) 1. Position Device Place midframe thumb stick down on ESD-safe surface. 2. Remove Antennas Using a plastic pry tool disconnect the two coax antennas from the mainboard. NOTE: The wires and pads on the mainboard are fragile.
  • Page 42 3. Remove Trigger Screw Using a T6 (Torx) driver remove 1 screw from the left and right trigger.
  • Page 43 4. Remove Caps Press the cap on the opposite side of the catch, shown below, and rotate off trigger.
  • Page 44 5. Remove Trigger Motors Gently remove the trigger rumble motors from the housing. NOTE: The motors are soldered to the main board. This solder connection is very fragile at both the motor and board ends. Take care not to damage the soldered connection 6.
  • Page 45 7. Remove Palm Motors Remove the palm motors from the mid-frame using a plastic pry tool to gently pry the retention clip back while pushing up on motor from the bottom. NOTE: The motors are soldered to the mainboard. This solder connection is very fragile at both the motor and board ends.
  • Page 46 8. Remove Thumb Stick Caps Secure device in one hand and grip thumb stick cap around the base with pliers. Turn plier counterclockwise to unscrew thumb stick cap. If you wish to not use tools, you can also connect your thumbstick cap and twist counterclockwise to remove. Repeat for other thumb stick cap.
  • Page 47 9. Remove Screws Using a T6 (Torx) driver remove the two marked screws that secure the mainboard to the mid-frame.
  • Page 48 10. Lift Out Mainboard Lift the mainboard out of the mid-frame, taking care not to damage the soldered connections to the motors. IMPORTANT: The mainboard is connected to the I/O board via a connector on the underside of the board. Light force may be required to separate the boards. NOTE: The audio jack module is wedged between the mainboard and I/O board.
  • Page 49 2. Install Mainboard Align locating holes on mainboard with locating posts in the mid-frame. Taking care not to damage the soldered connections to the motors and to align the connectors properly, lower the mainboard into place and pressing firmly to mate the connectors.
  • Page 50 3. Install Screws Using a T6 (Torx) driver install the two marked screws that secure the mainboard to the mid-frame. Turn screws until finger tight then tighten by an additional 1/8 turn (45-degrees) or until fully fastened.
  • Page 51 4. Install Palm Motors Gently press each palm rumble motor into the mid-frame. A plastic pry tool may be required to gently bend the retention clip back. NOTE: The motors are soldered to the main board. This solder connection is very fragile at both the motor and board ends.
  • Page 52 7. Install Caps Slide tab on motor housing into opening on the side of the cap. Rotate cap into position, ensuring posts on cap align with holes on the trigger housing.
  • Page 53 8. Install Screws Using a T6 (Torx) driver install 1 screw in the left and right trigger. Turn screws until finger tight then tighten by an additional 1/8 turn (45-degrees) or until fully fastened.
  • Page 54 9. Install Antennas Position the left antenna on the left connector on the mainboard and press down to connect. Repeat this process for the right antenna. NOTE: The wires and pads on the mainboard are fragile. Take caution not to break the pads from the mainboard.

  • Page 55: I/O Board Replacement Process

    I/O Board Replacement Process...
  • Page 56 I/O Board Replacement Process Preliminary Requirements Required Tools and Components Tools T6 (Torx) driver • Anti-static wrist strap (1 MOhm resistance) • Soft ESD safe mat • Microfiber / lint free cloth • Components I/O Board (Refer to Illustrated Service Parts List) •...
  • Page 57 Procedure – Removal (I/O Board) 1. Remove Screws Using a T6 (Torx) driver remove the 4 screws securing the I/O board to the mid-frame. 2. Remove I/O Board Lift the I/O board out of the mid-frame. Procedure – Installation (I/O Board) 1.
  • Page 58 Place the I/O board in the mid frame. 2. Install Screws Using a T6 (Torx) driver install the 4 screws securing the I/O board to the mid-frame. Turn each screw until finger tight then tighten by an additional 1/8 turn (45-degrees) or until fully fastened.

  • Page 59: Button Replacement Process

    Button Replacement Process Button Replacement Process Preliminary Requirements...
  • Page 60 Required Tools and Components Tools Anti-static wrist strap (1 MOhm resistance) • Soft ESD safe mat • Plastic tweezers • Components ABXY Buttons (Refer to Illustrated Service Parts List) • Prerequisite Steps Discharge the battery For devices with rechargeable lithium-ion batteries that power on, fully discharge the battery before beginning repair.
  • Page 61 Procedure – Removal (Buttons) 1. Remove Keypad Lift keypad from the mid-frame. 2. Remove Buttons Turn mid-frame over and allow buttons to fall out of mid-frame.
  • Page 62 Procedure – Installation (Buttons) 1. Install Buttons Insert buttons into the mid-frame making sure the alignment posts align with the slots in the mid-frame. IMPORTANT: Buttons are keyed and cannot be inserted into the incorrect position. 2. Install Keypad Install the keypad into the mid-frame, making sure that the keypad aligns with the buttons.
  • Page 63 3. Install I/O Board Install the I/O Board as detailed in the Procedure – Installation (I/O Board) (page 55) 4. Install Mainboard Install the Mainboard as detailed in the Procedure – Installation (Mainboard) (page 39) 5. Install Bumper Install the Bumpers as detailed in the Procedure – Installation (Bumpers) (page 26) 6.