To successfully complete this project you will need to have and use the Service Manual (SM) for the printer. Steps that are thoroughly covered in the SM (Section 4:Repair Information, Removal) will not be detailed here. I will add (SM) to those steps covered in the Service Manual. For the location of parts on the bottom of the Paper Platform see photos.

In this step you will be opening up the printer and exposing the Paper Platform for cutting. As you remove each part be sure to keep track of which screws were removed. You might want to tape the screws to the part or label them. Removal of some of the subsections below may require removal of other subsections or parts, so pay attention to the SM. To replace a subsection or part, reverse the removal steps. Using the SM as a guide do the following:

Remove the Right Cover (SM). It is the side with the access door.

Remove the Left Cover (SM)

Remove the Lower Front Cover (SM)

Open the Front Door.

Remove the Paper Feed Guide with the 6 small rollers. It is held in place by 2 screws on each side, not by the 8 screws on top. Discard it.

Remove the Manual Feed Paper Guide [Photo] and save it and its 2 screws. You will use it later.

Remove the Transfer Roller (SM). Be sure to remove and save the small spring under the right bearing clip and save it. The spring on the left side is attached to the transfer roller cable and should not be removed. The left bearing can slide off the transfer roller, so remove it and put it safely aside with the spring. Note that the clips on the bearing are oriented to the outside of the shaft. Also note that the bronze bearing can slide out of the clip and get lost if you are not careful.

Close the Front Door and remove and discard the pivoting beige Paper Holder.

Remove the Rear Door and Cover (SM).

Remove the Top Cover Assembly (SM).

Remove the Rear Exit Guide Assembly (SM) – Note that the longer screws are at the top.

Remove the Fuser (SM). The only part we need from the Fuser assembly is the connector and cable to the Exit Sensor. Cut the cable where it enters the Fuser, save the cable and discard the Fuser.

Locate the Thermistor cable on the Controller Board at J-12. Cut the cable leaving about 1.5 inches of wire. Remove the connector and solder a 2.7K resistor across the two wires. This resistor makes the printer think it has a Fuser heated to 200 C still attached. Without this resistor the printer will error out when booting. The resistor can be covered with tape or heat shrink. Replace the connector with its resistor at J-12 [Photo].

Remove the top rear 2 screws on the Rear Exit Guide assembly (save them) and remove the top section with the Narrow Media Sensor. Take the bottom section and remove the rollers and the reversal solenoid. Remove all the gears and small rollers. You will not be using the gears, rollers, or solenoid. Remove the Narrow Media Sensor and its flag from the top piece. Remove the piece of tape with its attached "bristles" and remove the 4 black plastic holders. You should now just be left with two bare green plastic pieces [Photo]. Replace the top section on the large lower section and screw them together with the two screws you saved [Photo]. Save the Narrow Media Sensor and its cable – you will be using it later!

Replace the stripped down Rear Exit Guide assembly using only the 4 upper screws (SM). Be sure to put the longer ones in the top holes.

Replace the top cover Assembly(SM).

Turn the printer upside down.

Remove the LVPS/HVPS (power supply) (SM). Remove and discard the thick 2 wire cable to the Fuser power supply. When removing the power supply note that one screw is different than the other 3 – that one screws into the plastic. Make special note of where the power supply tabs go under that screw. As you are removing the power supply, note which cable goes where and their orientation. Remove the Transfer Roller cable connector first using long nose pliers to pull it sideways out of its slot. Note its orientation. Press the connector tab to remove the two and three pin connectors. The multipin connector just pulls out.

Remove the 3 screws holding the power supply shield and remove the shield.

Remove the Duplex Assembly (SM) and discard it.

Remove the Main Motor Gear Drive Assembly (SM). Be careful detaching the motor cable. Since removing the door link (fuser link) will allow the door to "hang" open, disconnect the Operator Panel cable connector (J5) to avoid tension on the connector. You can also remove the door at this time to provide easier access to the Paper Platform.

Remove the Media Feed Clutch (SM) and discard it.

Remove the Media ACM ASM Feeder Mechanism (SM) [Photo]. All of these parts can be discarded, so it does not matter if you damage them in removal.

Remove and discard the pivoting plastic piece and spring that sits just behind the paper drive shaft and rollers [Photo].

Remove the Toner Patch Sensor [Photo]. It is held in place by 2 screws in the bottom of the paper platform, near the Media Feed Mechanism. Also remove the spring loaded sliding plastic window located just behind the Toner Patch Sensor These parts, too, can be discarded.

Remove the screws holding the Paper In Sensor (PIS) and the Duplex Sensor in place [Photo 02]. Each is held by one screw. Remove the wires to these sensors from the wire guides. Cut the wires to the Duplex Sensor close to the connector (J27). Be sure you are cutting the correct wires (Red/Black/White).

Remove the wires going to the Manual Clutch Solenoid from the same wire guide and weave it into the wire guide for the Main Motor cable [Photo].

Remove the screw holding the Manual Feed Paper Sensor (MFPS) in place [Photo]. Cut the cable near the sensor and pull the cable back into the controller compartment. You will not need the sensor but you will need the cable and connector.