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The printer or the drum/toner unit may cause the grinding or clicking noise.
Power off the printer and open the front cover.
Remove the drum/toner unit and close the front cover.
Power the printer back on.
If the grinding or clicking noise dose not occur when the drum/toner unit is removed from the printer, then the drum/toner unit is the cause of the noise. Install a brand new drum unit and/or toner cartridge may be necessary to stop the noise.
Opened up the back and found there is a plastic cog wheel on the end of an orange drum, which must be the Fuser Unit, which was damaged. So the paper was getting as far as the drum but the rollers to pull it through the Fuser Unit were not going round. A new Fuser Unit seems to be about £99 plus VAT and I don't supose a new printer is much more than that. So if anyone has a spare Fuser Unit for a Brother HL 5140 which is still in good working order I would be happy to consider buying it. Alternatively I have 2 x spare drums DR3000 and 1 x toner TN3060 for sale !!
There is likely a problem with your fixing unit (also called a Fuser).
This is a device at the exit of the printer that squeezes the paper
between a pressure roller and a heat roller. The heat is what "fixes"
the toner onto the paper.
Either your paper is being fed crooked, or there is a problem in the fixing unit itself.
Remove your drum/toner cartridge. Look into the empty chamber of the
printer and see if you can see any objects or bits of paper. Clean it
out as best you can.
If your toner and drum are separate cartridges, separate them and make
sure they don't have any bits of paper stuck between them. If they are
both contained in one cartridge, then skip that last step.
Remove your paper tray and make sure the tabs are set correctly. There
should be a tab at the back to snug tha paper length wise, and one at
the side to snug the width. Setting these correctly will help prevent
If you can see your paper pickup roller just over top of where the tray fits, make sure it is clean and not too badly worn.
Try printing something but turn the printer off about 1/2 way through
the print cycle. Open the door and remove the drum. The sheet of paper
should be stuck inside the drum. Examine it and see if it was feeding
crooked. After examining it, remove it carefully and throw it in the
trash. Don't touch the type as it is not fixed and will dirty your
hands or clothes.
If the paper in the drum was straight, then there is a problem with
your fixing unit. If the paper was crooked, then there is a pickup/feed
It sounds like you need a new electron or electrode I forget exactly what they call it, this negatively charges the paper as it passes over the positively charged toner drum allowing toner too stick to the paper where required, the lower the negative charge is the less toner that can positively stick to the paper, creating a light black or grey print. This generally occurs with age but should not be too hard to replace by yourself, just expensive.