May 17, 2017

Xbox 360 Controller Shell & Thumbstick Replacement

Introduction

This replacement guide will show you how to replace both the shell and thumbstick of an Xbox 360 Controller. Our trial actually included 3 different controllers; one in which had a faulty thumbstick, one in which had broken bumpers and another broken thumbstick but a very cool shell, and one generic Xbox 360 controller. However, for the sake of this guide, we used generic terms, assuming you are only using 2 controllers.

Step 1 Ensuring Safety
Image 1/1: This is to ensure that there are no electric currents traveling through the remote, ensuring you will not be shocked.
Remove all batteries or power sources from remote.
This is to ensure that there are no electric currents traveling through the remote, ensuring you will not be shocked.
This is very important.

Step 2 Replacing the Shell
Image 1/1: Keep the screws in a safe place to ensure you will not lose them.
Using a TP Torx T8 Screwdriver, remove all 6 screws from the back of your controller.
Keep the screws in a safe place to ensure you will not lose them.

Step 3 Replacing the Shell
Image 1/2: Remove hidden screw from location of sticker with the same TP Torx T8 Screwdriver.

Remove barcode sticker from back wall of battery port.
Remove hidden screw from location of sticker with the same TP Torx T8 Screwdriver.

Step 4 Replacing the Shell
Image 1/2: This will leave you with 2 separate pieces. Disconnect rumble motors, using fingers on sides of connectors.

Pry open the controller. Optionally, gently push in the thumbstick to eject the back half. (Some buttons may fall out.)
This will leave you with 2 separate pieces. Disconnect rumble motors, using fingers on sides of connectors.

Step 5 Replacing the Shell
Image 1/1:
To remove bumper housing and bottom piece, pull away from the shell (along the axis of the screwposts).

Step 6 Replacing the Shell

Image 1/2: Remember to ''keep small parts in a safe place'' to prevent the loss of a part.
Remove all mesh and buttons from controller, as well as the motherboard.
Remember to keep small parts in a safe place to prevent the loss of a part.
Later photo will clarify which button goes in which hole.

Step 7 Replacing the Shell

Image 1/2: Using 1.5 crosshead screwdriver, remove these screws and "store them in a safe place."
To remove arrow keys, locate the screws hidden within the key.
Using 1.5 crosshead screwdriver, remove these screws and "store them in a safe place."

Step 8 Cleaning the Controller

Image 1/1: '''Do not consume rubbing alcohol.'''
Clean shells and buttons with rubbing alcohol if needed.
Do not consume rubbing alcohol.

Step 9 Reassembly

Image 1/2: Place mesh back onto buttons.

Insert buttons into new shell as pictured.
Place mesh back onto buttons.

Step 10 Reassembly
Image 1/3: Replace the screws and place mesh over keys.

Snap arrow keys into hole.
Replace the screws and place mesh over keys.

Step 11 Reassembly

Image 1/3: Re-attach rumble motors. Note orientation of T-slot in connector.

Place the triggers and the motherboard in their respective places.
Re-attach rumble motors. Note orientation of T-slot in connector.

Step 12 Reassembly
Image 1/2:

Close controller and replace the screws with the TP Torx T8 Screwdriver.

Step 13 Replacing Thumbstick
Image 1/3:

Complete steps 1-4 on the controller with the faulty thumbstick.

Step 14 Replacing Thumbstick
Image 1/3: Place the new thumbstick onto its base, pushing it down as far as possible without breaking the base.
To remove thumbstick, pull the thumbstick vertically off of its base.
Place the new thumbstick onto its base, pushing it down as far as possible without breaking the base.
If you have purchased the wrong style of thumbstick, superglue, hot glue, or any other adhesive should work fine. Simply use a needle to put some adhesive and/or glue into the hole.

Step 15 Replacing Thumbstick
Image 1/3:

Once your thumbstick is in place, complete steps 9-12 to reassemble.

Author
victoriabethhopkins
Member since: 06/05/2015
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