There is a nasty grinding/slipping sound from the drive up to my fuser.
I get the impression that the fuser roller is very stiff and the drive train is struggling and slipping sprockets every so often.
I have tried lubricating what I can see of the fuser roller with little effect.
Is it possible to disassemble the fuser and lubricate it?
Shortly after I poseted the problem. I went back and "tricked" the top cover switch into thinking the top cover was closed by pressing the cover sensor with a pen and then tried printing a page. I noticed that the grinding was happening as the printer was spinning the black toner cartridge. By replacing the cartridge this stopped the noise. It could very well have been any of the cartridges, so you may need to do some trial and error.
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Post the exact error message indicated on the printer LCD. 13.01, 02 paper feed issues, worn rollers or jammed paper inside of paper feed assembly.13.05, 06 fusing assembly issues, broken sensor flag in fuser or worn busing on fusing rollers (fusing assembly will be noisy or making grinding sound.) If this the issue being noisy, the fusing assembly has to be replaced along with one of the drive gears, about a 30 min. of work.
Many dryers use rollers or wheels to support the clothes drum. When these rollers are worn, they can be noisy. You should replace the whole set of rollers at the same time.Dryers have a tension or idler pulley that keeps tension on the main drive belt. When it's worn, it can be noisy. When that happens, don't lubricate it. Just replace it.Some dryers support the clothes drum in the rear with a center spindle instead of rollers. The spindle may be a ball-and-socket type support or a shaft through a sleeve. When the components are worn, they may squeak, squeal, or rub. You can't repair them. Just replace them when they're worn.
You need to check a number of areas, but first try to determine where the noise is coming from...
1) First, where is it jamming...If under the cartridge, the cartridge drum may be too tight. If you have another or an old one (even if empty) try switching it out.
2) If the sound is coming from the front, your manual feed rollers (front) or main paper tray pickup rollers or gears (below) may be slipping.
3) If the sound is coming from the rear, check the fuser gears. It will have a main, big gear that meshes with the big drive gear (swing gear) inside the printer. The fuser is the accessed by removing the rear cover. The fuser can be very hot, as its job is to fuse the toner to the paper just before it exits into the bin. Let it cool off, then remove, inspect the gears for wear, re-seat it and test print--listening again to see if the sound is still there or gone.
4) If the sound is coming from the top rollers where the paper exits, check the gears that drive these rollers for wear and/or skipping teeth.
One of these will be the culprit. The hardest part is isolating the source of the sound.
Probably a broken Hot Roller gear in the fuser. The fuser is the section in the back, that presses the print between a pair of hot rollers to melt the powdered toner into the paper, making the image permanent. That combination of heat and pressure makes the fuser vulnerable to breakage in any laser printer or copier. The HR (hot roller) gear is a ring around one end of the heated roller, and it sometimes breaks apart. The MFC 9880 isn't listed on Brother's US service website, so I can't tell you whether you need to buy a whole fuser assembly or just that gear.
The grinding noise is the clashing of gears. The fuser is composed of 2 rollers, a metal or ceramic with a heater inside (bulb) and a silicon roller to apply pressure. The 'hot' roller is geared and the silicon roller can be geared or free floating. There is at least 1 paper sensor in the the fuser to let the unit know whether paper is there and there when it should or should not be. Sometimes, the sensor gets slightly dislodged and can actually cause a jam. If you are hearing a gear clash, the paper is being pushed through the machine and instead of being pushed through the fuser, it stops because the fuser rollers are not turning. The rest of the machine keeps pushing, crinkling the paper. If there is crinkling, then gears that drive the fuser need to be checked. It is this gear cluster and/or the fuser that need to be replaced.
Probably caused by the toner cart. Only use genuine new Brother brand supplies. Remans fail quite often with Brother machines. Possibly bad gears on fuser drive. But with the poor print quality, I suspect it is the toner.
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.