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DIY Fix the d-pad on the Xbox 360 control pad (more than just sanding)

Step 1Open and dissasemble the controller (security bits not required)

Open and dissasemble the controller (security bits not required)
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  • security.jpg
  • thedpad.jpg
  • smallscrews.JPG
  • dpadout.JPG
Open the controller (there are lots of pictures on-line) The hardest thing for me was realizing there's a screw under the sticker under the battery pack. (Opening and breaking this sticker probably voids your warranty). On the wireless controller there 7 screws in total.

You need a Torx-9, but I didn't need a security bit to open the screws. Instead I inserted a small screwdriver and twisted until the security nub broke clean off (allowing the T-9 to fit perfectly).

The back sort of pops off from the top. Pull straight out, to avoid damaging the battery contacts that hang off the main board and slide into the controller back. Also, it helps to hold down the triggers.

Try to keep the controller face down when opening. This will keep the buttons from spilling out every where until you are ready for them.

With the back off, remove the main board -- I found applying light pressure to the analog pads helped. Notice the rumble motors are just sitting in the wells and are attached to the main board by jumpers. Leave them plugged in but move the board carefully (don't let them hang and stress the connection point).

Now, flip over the top and knock out all the buttons. Don't lose them! Also, don't worry, they are keyed, so they only fit in the correct holes and only fit so they are oriented the correct way.

Lastly, you need to get the D-Pad mechanism out. Unscrew the two small screws shown and gently apply pressure to each of the clips in the D-pad mechanism.
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Author:walletandgromice