Question about Brother IntelliFAX 4100 Laser Fax

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Gear making a grinding noise

It seems to be some kind of paper gear that is grinding behind the toner/ drum cartridge. It makes the noise whether the toner/ drum is in the machine and also when it is out of it, when the front door is closed. Sounds like something is stuck or a gear is stripped. It is a loud noise. Can this gear be replaced? Also, I'm not sure how to open the machine in the back so I can see the gear to see what the problem is. -Jan

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  • jdawson265 Jan 30, 2008

    Thank you for your advice on this. We've decided to replace the fax machine instead of trying to repair it. -Jan

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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.

Posted on Jan 30, 2008

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Did you try a new toner, sometimes the drive gear on the toner it self is bad

Posted on Feb 17, 2008

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Having a clicking noise problem when installing a new toner cartridge into the fax machine. Reusing the old cartridge makes the noise go away. There is nothing wrong with the new toner (we have 2 and both...


You state that you have 2 new toners and both make a noise, but the old one does not. If both the two new toners came from the same source then it is possible that the vendor has a quality control problem and manufactured several defective cartridges. It does happen. If these are not genuine Muratec toners, that makes it all the more likely because often they are remanufactured and attention was not paid to details. Is the old cartridge from the same vendor and does it bear the same brand name if it is not a genuine Muratec item? 15 years in this business tells me that if the old one is quiet and the new ones are noisy, something is wrong with the cartridges, not your machine.

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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.

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look at front of machine where your received faxes come out. you will see a couple of rollers there. unplug fax, and while watching the rollers, plug in and see if they turn when machine starts rotating. if they don't, you have a broken heat roller gear. another thing can cause this is a bound up toner cartridge. try another if rollers are turning. last but not least, your old drum possibly damaged your drum drive gears.

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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.
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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.

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No there is no configuration page. The red blinking light means you have no paper under your blue tray or the paper empty sensor is broke. To identify the noise open the lid then close it, if you hear the noise while the fax is warming up then most likely you have a bad gear that meshes with the fuser drive gear, although it could also be the toner or drum. If it's not the toner or drum I stongly recommend a service technician , he should be able to provide an exit tray.

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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

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1st prob seems to be with the paper feed roller not meshing at the gear. Probably a broken piece on the lower document tray assembly. No real fix for this unless you can strip it out and haywire it.

2nd prob is probably a poorly meshing drum unit. Examine the gear teeth on both the drum and the machine. As you have replaced the drum already (presumably with a brand new one) You might possibly find a missing or badly worn tooth on the messhing gear in the machine.

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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.

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