DualSense BDM-010 intermittent hardware issue

PS5 Questions DualSense Controller
1

Hi everyone,

I’m trying to repair a DualSense BDM-010 with a very strange intermittent fault.

Background

  • Bought the controller as non-working.
  • Battery voltage is OK (3.92 V).
  • No signs of liquid damage or previous repair attempts.
  • The controller was initially completely dead (no LED, no USB detection).

What I’ve done

  • Cleaned the pressure-contact membrane and PCB pads with IPA.
  • Replaced the large transparent contact membrane with a brand new one.
  • Added a thin foam shim to increase the pressure between the membrane and the PCB. This made the controller much more reliable.

Current behavior

The controller now powers on and works, but the issue is not completely gone.

Wireless mode:

  • The controller connects normally to the PS5.
  • Buttons and analog sticks always continue to work correctly.
  • However, from time to time:
    • the white LED turns off and back on
    • haptic feedback stops working, then comes back later
    • audio output sometimes switches from the controller speaker back to the TV, then later returns to the controller.
    • During these events, the controller usually does not disconnect from the console, and inputs continue to work.

USB mode:

  • Same behavior on both PC and PS5.
  • Tested with multiple USB data cables.
  • Sometimes Windows detects the controller normally.
  • Sometimes the white LED repeatedly turns on and off and USB becomes unstable.
  • Occasionally everything suddenly becomes stable again, even if I gently twist the controller or move the USB cable.

Additional information

  • Pressing the reset button on the back once completely revived the controller after it appeared totally dead.
  • I originally suspected a mechanical fault, but the symptoms are now inconsistent.
  • Since replacing the membrane did not solve the problem, I’m wondering if this could be an intermittent power rail, PMIC, regulator, cracked solder joint or another known BDM-010 issue.

Has anyone seen similar symptoms on a DualSense BDM-010 or knows which area of the board should be investigated first?

Any ideas are welcome.
Thanks in advance for your help..

2

Hello,

Problem is finally solved, and controler is working pretty well.

I managed to fix it by heating the motherboard with a hot air gun.

I had noticed that pressing on the motherboard made the problem disappear.
The hot air solved the problem; it was probably a bad connection or a cold solder joint somewhere.

So far, so good. I’ve played for several hours and it’s still working. We’ll see how it holds up over time.

Hope it could help someone.