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Re: gear grinding noise
Sounds like it could be the toner cart is not mating properly. Sometimes this could be simply that the spring and flap arrangement on the plastic case of the cartridge has become misaligned. It is not necessary to have the flap(cover) present once the cartridge is installed in the machine. Just remove it in it's entirety if you can't re-align it.
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A knocking noise is typically a bad bearing, probably in the fuser. You can try lubricating the bearings (once the fuser has cooled down) and see if the noise goes away. If not, the bearings might need to be replaced in order to get rid of the noise.
If you pull the drum out of the machine. Close front cover. is the noise still there. If it is then you have a broken fuser gear. If noise is not there remove the toner cart. from drum reinstall the drum unit in machine see if noise is there. if noise is there then it will be the drum. If not reinstall the toner try that if noise comes back then it is your toner cart.
Mine was indeed a gear problem. Took off the top cover and poked around. Found two areas that may have caused the grinding. 1. The lower roller shaft had slid to the left out of it's groove. By removing the handset cradle (3 release tabs are accessed underneath the toner hatch.) I could loosen the "gear box" (a black contraption with all the gears inside) and then snug the bottom roller into proper position. 2. I removed the "gear box" to look around. Don't know if I dislodged one of the gears while doing so, but noticed one was dislodged ;-) This required opening up the gear box by removing 2 screws and lifting off the motor. Then i could get at a gear that had come loose from a claw sort of piece. Note: the teeth of the loose gear needed to be on the motor side when sliding it back into the claw thingy. It seems to use a metal clip for friction control and perhaps proper spacing.
I noticed "some" wearing of gears, but doubt this is an issue. This machine has been used VERY hard for years and now, just by re-aligning things, it works once again.
My googling barely found any mention of troubleshooting this machine, so I shudder to think what finding parts would be like.
It could be a bad drum unit. If the drum doesnt turn smoothly it will make a clicking or grinding noise since it is gear driven. Take out the drum and turn the gear with your thumb. turm towards you. If difficult Thats it. It also could be a fuser gear. good luck Lawrence
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.
Does it only make the noise when printing. Do you hear the noise when sending out faxes? I have heard grinding noises onlt when using poor quality toner refills, or the fuser gear and or drive gear asm is stripped. First try a known good OEM toner.