Question about Brother MFC-8440 All-In-One Laser Printer

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Gear Racheting Noise

Disassembled back and side of unit - grey driver gear that drives the fuser appears to be stripped. Is that gear available - how do you remove that gear? Fuser gear appears to be okay. Installed new drum unit and toner cartridge but still had noise. Disassembled and pulled fuser - that gear looks okay, but the drive gear appears stripped.

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Gear Racheting Noise - b2829b2.jpg 2103e2d.jpg
Not a easy gear to get to, entire side frame must be removed. I always just replace the whole left frame as pictured, but really you only need to replace gear pic at top, like I say not easy, take pics so you know how to reassemble it.

Posted on Feb 11, 2008

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You may not be able to find that 1 gear, usually they only sell parts in assembly, so that would be like the main gear drive assembly.

but go to this site and take a look, they do sell fuser gears
maybe then can help you further

thanks for rating

Posted on Jan 10, 2008


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Posted on Jan 02, 2017

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Related Questions:

1 Answer

Where is the fuser located on MXC 311

The fuser unit is located in the right hand side of the machine. If you open the right door, inside the upperpart of the machine you will see 2 grey handles, 1 towards the front of the machine, the other towards the rear. If you pull these handles out you can then remove the fuser unit. There are 3 known faults for loud fuser noises,1 is the fuser drive gear inside the machine strips the teeth on it, second, the main drive gear in the rear of the machine strips the teeth(usually caused by the 1st problem getting broken teeth stuck in the remaining teeth causing the drive motor to strip the main drive gear) & thirdly, the pressure release mechanism breaks on the fuser unit itself. If it is any or these then unfortunately you will need the assistance of a dealer to replace the damaged parts.
Hope this helps.

Oct 13, 2014 | Sharp Office Equipment & Supplies

2 Answers

Fuser error

Your machine is in need of a new fuser unit. HP LaserJet 2400 Maintenance Kit Installation - Fuser (Part 1 of 2) Installing the fuser. Turn the power off and unplug the printer. Wait 20 minutes for the printer to cool.
Open the back door of the printer, using enough force that the door opens completely and the hinge locks disengage, as shown below.

2400_openbackdoor.jpg Remove the 2 screws circled in red below.

2400_removebackscrews.jpg Close the back door, and then flip the printer so that it rests on its face. 2400_closebackdoor.jpg 2400_flipprinter.jpg

Next swing open the paper guard which shields the back of Tray 2 when it is installed.


Looking inside the Tray 2 cavity, use a flatblade screwdriver to release the two tabs--one on each side of the rear cover.
2400_pryleft_backgate.jpg 2400_pryright_backgate.jpg

Next remove the rear cover from the printer by pulling down and away.


Fuser Installation Continued . . .
Pry the grey DIMM cover loose and remove it.


Use a small flatblade screwdriver to disengage the tab on the connector shown below and unplug the connector.


Next (on the right hand side) remove the small black plastic cover, located near the green fuser gear, which hides the other fuser wires.
2400_removewirecover1.jpg 2400_removewirecover2.jpg

Then unplug the two connectors shown below and free the yellow/white wire from its guide clasp.


Now remove the four screws holding the fuser in place (shown below).


Now remove the black plastic piece shown below, the duplexer inlet guide. Gently pry the tabs on both ends loose and slide/rotate the guide back towards the fuser to release it.
2400_removeduplexguide2.jpg 2400_removeduplexguide3.jpg

Now you can remove the fuser, just pull it straight out towards you. Don't install the new fuser until you've replaced the main motor gear, as shown below.

Replacing Fuser Drive Gear

With the fuser removed, look into the printer and locate the main fuser drive gear on the left side of the fuser cavity (gear circled in red below).


Use a flathead screwdriver to pry the gear's release tab and remove the gear by sliding it off its metal bar.

2400_gearreleasetab.jpg 2400_removegear.jpg

Slide the new gear onto the metal bar--make sure the gear's release tab faces outwards so it will be accessible again--and lock the gear firmly in place.

Now repeat the fuser removal process backwards as you install the New Fuser:

Insert the new fuser and replace the four fuser screws. Replace the black plastic duplexer inlet guide, making sure both tabs click in place. Re-plug the single connector on the left side, and the two connectors on the right side. Replace the wire cover on the right side. Reinstall the DIMM cover. Finally, replace the back cover with its screws.

This is a difficult installation which should be done by a technician. Good luck with it !

Sep 23, 2011 | HP LaserJet 2420 Printer

1 Answer

Groaning noise

Remove back door & fuser assm, in fuser driving gear mechanism located left side replace 19 teeth gear..see the link for the gear recognition..,r:2,s:50&tx=138&ty=55

Sep 20, 2011 | HP LaserJet 2420 Printer

1 Answer

MWe have a sharp al-1631, only used for coping of documents. It has been a great! machine and still serves us well. But it is making a very loud grinding noise, almost like nylon gears grinding (I...

Odds are, that the fuser driver rachet gear is stripped out and you may also have a broken gear on the upper fusing roller. It could be one or both..... You will have to take the fuser unit out and look at the gears. If you do take the fuser out.... Unplug the copier from the wall...... There are just two screw that take the fuser out, you will have to take off the back cover to unplug and remove the fuser unit.... Good Luck

May 19, 2011 | Sharp AL 1631 Copier

1 Answer

No error messages, but there is a loud banging noise during printing that just started. Cannot locate the source.......

Could it be more like a clicking or grinding noise? That would be the swing plate assembly gears. Those gears connect the drive system to the fuser, driving the fuser gears. There is no workaround, it is a replace only. I would suggest contacting a service provider. The swing plate assembly has either a quick 15 minute fix or a tiresome and complicated up to 2 hour fix, especially if the screws get stripped out.

What happens is the fuser gears and the swing plate assembly gears bounce slightly, creating wear on the fuser drive gear and the swing plate gears. Over time they wear down enough that they start making noise and will eventually start causing jams in the fuser. If you notice a bunch of white dust that has an oily texture when you rub with your figures on the drive side of the fuser, that is the gear dust.

Good luck!

Apr 09, 2010 | HP LaserJet 4250n Printer

1 Answer

Hi. we have a Sharp AL-1631 copier. It recently has been making a fairly loud + fast clicking sound upon startup and usually wrinkles up the first page through. It seems like the white plastic spring...

Wrinking usually is caused by the fusing unit. This is the part that gets hot and "fuses" the toner onto the page. I doubt that the cartridges are the issue. If you were getting binding or gears popping in the cartridge then your copy quality would be severely affected. Fuser drive gear failure is common on these models. Also if the noise is inconsistent then your right side mounting screw may be loose. Look at the fuser assembly behind the right side door. It is black in color and has the little green tab on the lever that has all the teeth on it. Looks like this:

Once you have the fusing unit located then look on either side of the unit. There is 1 screw on each side. Make sure they are tight. Especially the right side as that is where the drive comes from and is under the most pressure. If the noise happens all the time then you may have a broken or damaged drive gear on the fusing unit (upper fusing roller drive gear) or the small gear on the machine that drives the fusing unit. You can remove the right side screw and pull the fuser out enough to look at the gears.
Good luck and thank you for using Fixya.

Mar 24, 2010 | Office Equipment & Supplies

2 Answers

Paper Jam E2 error

On this model, the fuser assembley is mounted to the machine mounts, two of them inboard and outboard.
If the fuser gear is not cracked, this fuser is driven by the white small drive gear on the machine.
This rests close the drive gear. Sometimes you can hear a thumping noise which is coming from the gear skipping over the fuser gear.
This gear needs to be replaced a very involved service process.
Call Xerox for further repair if this is the case. Also behind this gear are many other gears that can cause this same problem. Very involved and time-extensive to repair even for a trained Xerox technition.

Aug 11, 2009 | Xerox WorkCentre XD100 All-In-One Laser...

7 Answers

HP P3005 making grinding noises

this is a problem that HP refuses to acknowledges. Its caused by the gear that meshes with the main fuser wanders to the right as the printer prints. we are checking into a fix for this, since we are getting no cooperation for the manufacturer, Canon or HP. Canon makes the print engine

Apr 01, 2009 | HP Hewlett Packard LaserJet P3005 Printer

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Agitator in washer is making lots of noise

there is a racheting gear made of plastic under the agitater. if the tub is overloaded it will strip the gear.

Feb 22, 2009 | Washing Machines

2 Answers

Gear making a grinding noise

Not too good news I'm afraid. It sound like the fuser gear has failed. Generally the fuser unit (hot section or hot rollers in the back) need to be replaced. Usually when the gear has worn or failed the fuser rollers are also worn and need to be replaced. The gear can be replaced seperately but is a very risky operation and usually results in parts in the fuser unit falling appart due to age and wear, so it is best done as a unit. If possible do not run the machine as it can cause damage to gears around the fuser unit. The best option is to find out how much a fuser unit and labour to fit would be at your local service centre.

Jan 29, 2008 | Brother IntelliFAX 4100 Laser Fax

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