Reflow or Reball?
DISCLAIMER: Please note, these opinions are my own, and are based solely on my experience of fixing many, many game consoles. The following information is intended as a lay-persons explanation only and is not to be considered as scientifically accurate. It is NOT intended as a criticism of either Microsoft or Sony (or any game console manufacturer – I love gaming and it would not be possible without these amazing machines). This is intended for information purposes only, and should be read in context with other information that is freely available. Before commissioning any repair check your warranty status with your manufacturer – they may repair for free.
There are two main methods of fixing RROD, reflow and reball, so which is best?
With a reflow the existing solder is melted (reflowed) under the GPU. This has the effect of renewing the solder bond between the GPU and motherboard and removing any solder failures and oxidization. Done correctly it is effective and with better heat management (12v mod, hybrid fix) can be expected to be a long term fix.
A reball is certainly considered the most reliable and permanent fix as it involves replacing the lead free solder with leaded solder. Lead free solder is used by console manufactures largely because of the environmental concerns associated with using toxic products (such as lead). However, lead free solder is more brittle than a tin/lead solder mix and can break down over time, and given extreme changes in temperature. This is what leads to RROD in most cases.
Reflow
A quality reflow is done with a preheater and SMD/BRG rework station. Temperature must be controlled very precisely (I use direct contact on the GPU and laser temp guide). Temperature is critical with reflow as too little and you don't properly reflow the solder and too much you damage the board or GPU. All reflow must be done with a good quality gel flux.
Reball
A proper reball actually involves removing the gpu and replacing it, together with the lead free solder (the cause of rrod). This method must be considered superior to reflow, but it is also potentially more destructive (as extreme heat is used to remove the existing GPU) and is far more expensive than a reflow. Beware that there are many repairers who claim to do a reball, but it is actually a reflow (or they don’t know the difference). Price is usually a guide, as this is a time consuming job and usually includes the cost of a new GPU. If someone says they are doing it for $80 they are most likely doing a reflow, making extra money and hoping you won't know the difference (which you won't unless it fails).
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What is RROD?