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How to Remove and Replace Electric Bike Controller Housing


Hey, everyone. Peter at sixthreezero. I'm going to show you how to remove and replace the controller housing, which is this part here on our bikes where the battery slides into. This is the part that holds the controller, which is like the brains of the e-bike, and sometimes this needs to be replaced. So, I'll show you how to do that.

All we need are just a few simple tools actually, a Phillips. You need... I would use a small adjustable wrench. I think that it may be a seven-millimeter nut, but I'm not exactly sure because I don't have an open-end wrench that can fit in there that's small enough. So I'm not exactly sure of the size. I think it's seven-millimeter. I'm just going to use a small crescent or adjustable wrench and then some snips for zip ties.


Okay, so the first thing I'm going to do is use my snips here, and we're going to snip a few zip ties, okay? There's one down here for the motor for the wire goes to the motor, and I'm just going to go here and snip that carefully. Obviously don't want to snip the wire, just get the zip tie, and that'll be loose there. And then, there's a couple of zip ties binding all these wires together that go up to the controller right here. Okie doke. Now that's done. Now I will get the Phillips and the small crescent wrench. And we're going to go ahead and remove a couple of screws. We'll do this one first.

It's a little bit hard to access that nut in there.


But we do need to get that one to hold the nut stable while we unscrew the Phillips bolt there. Going to come right out. Here we go. Try not to drop it like I just did because you'll need it later for the new controller. There are a couple of other ones on the underside, but we can't get to those yet. We actually have to open up the front part of the controller here. There are just two Phillips screws. So it's super easy. Remove these two screws. Here's the first one. Here's the second one.


And then there are two little plastic tabs, one on either side of the controller. We're just going to push those in and pop the front of the controller housing out. You can just use the screwdriver to push it in, and the front panel will come out. It's just a little plastic piece. Then you can actually see the controller in here. Right here. It will come out like this. Okay. And keep that. And then what we need to do is we're going to take off the bottom two nuts. Actually, you can access those with the panel still on because the screw is inside the controller already.


You can just do this with the wrench. Take these two nuts off that are holding the housing to the rack. This might take a little time with this adjustable wrench. It'd be a little faster if I had a small, tiny ratchet.

Now, this controller should just kind of... The controller housing should slide out the rail unless I'm forgetting something. Oh yes. So the two screws can also come out. These are held in by themselves in the controller. So go ahead and pull those out. But that's why it only took one tool instead of both tools to use these because it actually is held in place by the controller housing, itself, while you're undoing the nut. That takes a little while to do. Now, the controller housing comes off like this.


So now that we remove the controller housing from the rack itself. We're just going to disconnect the controller from it, which is really quite simple. All we have to do is take the red and black leads that are coming from the prongs for where the battery inserts, and we're just going to pull these, separate these by pulling them apart. It's really that simple. And now we have the controller housing removed from the bicycle and now it's ready. We're ready for a new one if we need to replace this.

Okay. So now we're going to take the new controller housing, and we're just going to replace it. It's really just the exact opposite procedure. However, this video can be used for whichever, whether you need to take this off or reinstall it or both. Okay. So now I'm going to go ahead and take the leads from the prongs, and we'll put red to red. Snap those in until we have a nice positive connection and then black to black.


Here we go. And then, we'll put the controller housing right here and place and slide it underneath the rails. Probably a good idea at this point to go ahead and take that screw for the front part and insert it into the front part of the controller to keep it from sliding. I'll just hold it there. And then we can also take the nut and retighten it here to hold the controller in place temporarily.


I wouldn't tighten it down all the way through. Just like with anything when you're using separate fasteners, just keep everything loose until the final moment when you can tighten everything down together.

Okay. So now that we have the front screw in here just holding the controller housing in place, now we'll put in the two screws that go into the front part of the controller housing. And remember, these two have a little space in the housing where they slide into, and then they're actually held by the controller housing itself. So you don't need a separate tool. You don't need to use a Phillips to hold the screw in place while you put these two little nuts on these screws. So we'll get those started before we use the wrench to tighten them all the way up.

Here we go. Got them started, and then I can use this wrench. Now at this point, we want to get all the screws tightened down all the way before we put in the controller and then replace the front plate. Okay. So there we go. Now we have the screws nice and tight. Now we'll take the controller and place it carefully and in logically into the controller housing.


Push all the wires out of the way. And we'll take the leftover bundle of wires and move them towards the middle. And you'll see that there is an open area here in the front plate. That's where the wires are going to come out. And then simply take that front plate and snap it into place.


There we go. And now, we'll take those two front screws, and we'll finish up. Just two little guys put them back in the opening and screw it right back in.


Number one and number two.


So there you go. That's how you replace a controller housing for our e-bikes.


All right, thanks for watching. I really hope that was helpful. If you need any more help, please don't hesitate to contact us at 310-982-2877 or theteam@sixthreezero.com. Sixthreezero is spelled out. S-I-X, T-H-R-E-E, Z-E-R-O. Also, subscribe to our channel. And remember, it's your journey, your experience. Enjoy the ride.

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