All of a sudden a "clicking" noise istarted recently after the machine is turned on and is warming up. This lasts about 10 seconds. The same noise is heard after pressing the "START" button. A paper jam symbol appears. Crumpled / accordioned paper is jammed beneath the fuser. Even after clearing the paper ----- the same noise and jam occur.
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I suspect you have lumpy toner in the black cartridge and it will not turn properly. The sound is probably the impeller hitting hardended toner. Try another black toner but give it a good shake before you fit it and DONT empty the drum as you will lose the developer within it.
The fuser is the problem. Most likely the fuser will need to be rebuilt or replaced. Google a business called The Parts Drop. they have either the parts or the unit.
You may just have to take the fuser out and remove a badly jammed piece of paper in that module. Shut the machine off for a half an hour. Remove the back cover. You will then see on the left side a black plastic bracket with 3 plugs on it. Disconnect those 3 plugs. Then open the right side door and toward the top is the fuser. It has yellow caution HOT labels on it. There are 2 silver phillips screws holding it in. Remove the screws and then remove the fuser unit and see if there is a paper in there. There are 2 screws that you can remove and the fuser will kind of fold open to inspect for bent fingers or one out of place.
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.
your description points to a fuser assembly problem which is right where you looked. I'm not sure what that plastic piece is from. if it is black, it probably came from the fuser. That is a replaceable part, but I'm not sure you can still purchase them from Xerox.
Sounds like 2 different things going on.
The slow warm up is normally the toner cartridge is almost out of ink but not reporting it. It is trying to set up but there is not enough ink to do so.
The jams, if the machine is making it into the machine but not exiting, then you most likely have a broken gear on the end of the heat roller in the fuser
On the XD 100 if it is jamming when it is just entering the fuser, check the gear on the end of the heat roll.
Those frequently crack and or flat out break off.
That gear is easily replaced and inexpensive. If you require information where to purchase one, let me know via a message here.
I checked and you can purchase that gear for $14 or less.