Introduction: Replacing the Shell of a Wireless Xbox 360 Controller

Step by Step Guide to Replacing the shell of an Xbox 360 controller to a new shell. This tutorial can be used to help students have a basic understanding of hardware, electrical/computer engineering, and computer science principles through video games.


New Shell and Kit

Philips head Scredriver

Old Controller

Step 1: Organize Materials

In your kit (downloadable from amazon or other 3rd party sellers), you should have the new shell, controller pieces, 2 screwdrivers, and a prying tool. Make sure you have all of the necessary pieces as well as the older controller.

Step 2: Using Your Torx Security TA27 Screwdriver, Unscrew All of the Screws From the Old Controller

There are 7 screws on the back of the controller. Be aware, the last one is located behind the label on under the battery pack. You can just screw through the label. After that use the prying tool if needed to separate the top and the bottom of the case.

Step 3: Remove the Back From the Top of the Case. Then Remove the Motherboard

Be sure to keep all of the screws in together. Inside the case is the motherboard. Be sure to be careful when separating the case and do not force it. Remove the button pads from the front of the controller and set aside.

Step 4: To Replace Parts Start With the Triggers.

The trigger is held in place with an arm, and a socket. To release, you have to push the arm and socket out in opposite directions to free the arm from the socket, and then press the arm down until it closes.

Step 5: Flip Up the Trigger and Release the Springs. Then Replace the Triggers With the New Ones.

The trigger buttons will slide off the posts. Be careful not to lose the springs. We will use them later on the new trigger buttons. Get the new trigger buttons and be sure not to mix up the left and right buttons.

Step 6: Secure the New Triggers in Place.

Place the spring on the post inside the trigger button. The other end of the spring will go on the little plus icon on the mother board. You may need to remove the motherboard from the shell. Be sure to remove the battery pack as well.

(For easy placement, put the one end of the spring on the post inside the trigger. then hold it in place and press the trigger down until you feel it catch to the post.)

Be sure to take note of how the triggers from the old controller detached so you know how to put the new triggers on.

Step 7: Next, Begin With Replacing the Face Buttons.

You will now be working on the front side of the shell. There should be four buttons in the kit. They may not have the letters on them but that is purely cosmetic. The buttons will all fit in their respective slot so you may need to turn them around a few times or switch slots to make sure you have the right one. (I noticed the "X" button only had 2 notches while the other ones all had 3)

*Be sure to look at the size of the buttons because there are 8 in the kit, 4 of them are the A, B, Y, and X buttons, 2 of them are for the start and back buttons(these are smaller), 1 of them is for the guide button(This one will be largest), and the smallest button is the connect or sync button.*

Step 8: Replace the "Guide", "Start", and "Back" Buttons.

There will be a clear holder for the guide button (2nd picture). Insert this in first. Making sure that it is facing the right way. You will need to press it firmly into the slot. Then place the guide button inside by pressing firmly again. The start and back buttons will fit into their slots as normal. Then put the button pads back in place.

Step 9: Replace the D Pad.

The d pad consists of two parts. These two parts fit together. Put the front of the d pad (The part you use when playing) in the controller. Do this by lifting the shell up and putting in backside first so that the directional part faces out. Then, grab the second piece and make sure it aligns with the first piece. You may need to turn it around so they fit together properly. (If you need to you can use your hand to push the d pad back from the front side so you can fit the other piece on). The old D pad will have two tiny Philips head screws holding it in place, using your Philips head screwdriver, unscrew these so that you can add them to the new controller (if your kit doesn't come with two screws, mine did not) . Place button pad for the D pad in its position.

Step 10: Put the Sync Button in Place.

The tiny sync button. will fit inside the back plate. Do this by locating the little post on the inside of the back plate. The post is next to the slot for the sync button. place the hole of the sync button on the post so that it fits inside. The sync button will then face out the hole on the back plate

The sync button doesn't necessarily snap into place so it may be loose. If necessary you can heat up a paper clip (or another tool) with a lighter and press it onto the post of the sync pad so it won't slide out.

Step 11: Secure the Back Plate to the Bumpers.

Do this by fitting the bottom of the back plate to the two prongs on the bumpers. It should fit together like a puzzle piece. Then, secure the entire back onto the shell. This is done by locating the two posts on the front shell. These two posts will fit into the two holes on the back piece. (See 2nd photo)

Step 12: Add the New Thumbsticks

The old thumbsticks should easily slide off. You may need to remove the motherboard from the shell to get a better grip. You may also need to rotate the thumbstick until it fits on the motherboard properly. You can choose to only replace one if you want thumbsticks that are different colors.

Step 13: Put the Motherboard Back Into Its Shell. Reassemble

Be careful of the wires and hold everything in place. Now put the back shell with the motherboard and bumper onto the front case with the buttons. Be sure that you have everything in place tightly so it doesn't move out of place.

Step 14: Secure Shell and Pieces

Be sure to carefully put both pieces back together. Do not force anything but rather delicately place the controller back together. Close the shell and screw the pieces back together using the smaller screws from the old controller. Put the batteries from the other controller in the battery pack and secure it to the back of the controller

Step 15: Test It.

If done correctly, your controller should be working. When you press the guide button, the controller should light up notifying you that everything is connected properly. You should also test it on your Xbox 360 to ensure there was no damage to the controller in the process.

You will also want to test out all of the buttons. Make sure the buttons feel right when you press them and are also secure. If something does not feel right you will need to unscrew the case and revisit the buttons to be sure they are fitted together properly.

If everything works as planned, play some games and enjoy!