I have enjoyed my Roku HD for quite a while now. It's been reliable, pretty quick and overall, capable device. I have had an issue as of late though, and here is my adventure on trying to remedy it. I would first like to say this isn't a problem for all Roku players. I do believe the first generation Roku's set top boxes had an issue with their power supply, causing them to overheat. The problem I am having is with the 2013 Roku HD 2500X.
This is the only model to use the BCM*7208 400 MHz Processor in Roku's lineup. I also have a Roku 2 XS which uses the BCM*2835 600 MHz Processor and i have had very little issues with that model locking up.
Firmware updates over the past 6 months have helped lessen the issue for this player, but recently after watching a Twitch Podcast for 30 mins this Roku HD would start to lockup. I would then have to unplug the player and reset it again and when it would lock up again the pattern would continue. I did notice every time I would hold the Roku HD to reset it, it felt extremely warm even close to being uncomfortable to hold. The bottom was very hot. Keep in mind this is not in a cabinet, it's sitting right next to the TV with nothing covering it at all.
I wasn't sure if this was an issue with this newer low-end processor?
But I know being out of warranty I didn't want to throw it out quite yet. So being the Geek that I am I decided to modify the cooling or the lack thereof.
I was positive the Roku was freezing due to heat, so off to taking it apart.
Here some pictures on how to dissemble the Roku HD -2500X
First, you'll need to peel the sticker off on the back of the Roku. I used a small flat head screwdriver and slid it under to get it started.
Then remove the four Phillips head screws.
After you remove the bottom casing, you will see this. The bottom of the PCB and two more Phillips head screws that will need to be removed.
After you remove the two screws, the PCB will pop right out and you will be free to handle the internals and inspect the PCB. I didn't take a picture of the bare processor, but it has nothing on it, no heatsink or any type of cooling solution.
I had some left over thermal tape from a job earlier in the month and some left over aluminum heatsinks from a aftermarket video card cooler. I decided to use the two and create a cooling solution for the processor. I Used some alcohol wipes to first to wipe down the heatsink and processor. I then cut the tape into a small square and installed it on the bottom of the heatsink. I then placed the heatsink on the processor and held down firmly for about 10 secs. Installing in this manner proved to be strong enough to hold the heatsink in place.
Just enough height clearance.
Finally, I put everything back together the way I took it apart. For the last couple of days I have had zero issues with my Roku HD locking up. Success!
The unit still gets warm, but it's nowhere near as bad. I will update this thread if anything changes, but I wanted to post this in hopes to help others if their Roku is out of warranty and is experiencing the same issue.
Here is a link to an item you will need if you have no material to do this job. Very cheap, shipping may even cost you more?
Cheers!
http://www.frozencpu.com/products/1...ive_-_27mm_x_27mm_x_5mm_-_Anodized_Black.html

This is the only model to use the BCM*7208 400 MHz Processor in Roku's lineup. I also have a Roku 2 XS which uses the BCM*2835 600 MHz Processor and i have had very little issues with that model locking up.
Firmware updates over the past 6 months have helped lessen the issue for this player, but recently after watching a Twitch Podcast for 30 mins this Roku HD would start to lockup. I would then have to unplug the player and reset it again and when it would lock up again the pattern would continue. I did notice every time I would hold the Roku HD to reset it, it felt extremely warm even close to being uncomfortable to hold. The bottom was very hot. Keep in mind this is not in a cabinet, it's sitting right next to the TV with nothing covering it at all.
I wasn't sure if this was an issue with this newer low-end processor?
But I know being out of warranty I didn't want to throw it out quite yet. So being the Geek that I am I decided to modify the cooling or the lack thereof.
I was positive the Roku was freezing due to heat, so off to taking it apart.
Here some pictures on how to dissemble the Roku HD -2500X
First, you'll need to peel the sticker off on the back of the Roku. I used a small flat head screwdriver and slid it under to get it started.

Then remove the four Phillips head screws.

After you remove the bottom casing, you will see this. The bottom of the PCB and two more Phillips head screws that will need to be removed.

After you remove the two screws, the PCB will pop right out and you will be free to handle the internals and inspect the PCB. I didn't take a picture of the bare processor, but it has nothing on it, no heatsink or any type of cooling solution.
I had some left over thermal tape from a job earlier in the month and some left over aluminum heatsinks from a aftermarket video card cooler. I decided to use the two and create a cooling solution for the processor. I Used some alcohol wipes to first to wipe down the heatsink and processor. I then cut the tape into a small square and installed it on the bottom of the heatsink. I then placed the heatsink on the processor and held down firmly for about 10 secs. Installing in this manner proved to be strong enough to hold the heatsink in place.

Just enough height clearance.

Finally, I put everything back together the way I took it apart. For the last couple of days I have had zero issues with my Roku HD locking up. Success!
The unit still gets warm, but it's nowhere near as bad. I will update this thread if anything changes, but I wanted to post this in hopes to help others if their Roku is out of warranty and is experiencing the same issue.
Here is a link to an item you will need if you have no material to do this job. Very cheap, shipping may even cost you more?
http://www.frozencpu.com/products/1...ive_-_27mm_x_27mm_x_5mm_-_Anodized_Black.html
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