Brother HL-2040 -- Cover Removal

Following is the procedure to remove all the covers.

Items '1)' and '2)' needn't be removed for service access to the machine's innards. There's no shortcut for getting the top cover off; the inner chute (delivery assembly) has to come out the back first. Just follow the procedure from step '3)' onward.

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1) Paper Tray Front Cover
- Two M4x12mm pan head threading screws.
- There are two upward-gripping claws either side of the separation pad still holding the cover in place. Pry the cover away from the body of the tray and the claws will pop free.
- Shove the cover downward to free the hooks at the bottom.
- NOTE that the platform elevation shaft's end is free to flop around when the front cover is off.

2) Front Door
- NOTE: There's no graceful way to remove and reinstall this item; it's all flexing and forcing.
- Disengage the black link at the left.
- Pry off the left side curved way.
- Force the cover rightward to free it.

3) Left Side Cover
- One M4x12mm pan head threading screw at the front under the front door.
- One M4x12mm pan head threading screw at the rear under the back door.
- Pry free the front lip at top and bottom.
- Pry free the rear lip at the top.

4) Right Side Cover
- Same as for left side cover.

5) Back Door
- Flex the curved arm to force it off its stop pin and the door can come away.

6) Back Door Stop Pin Block
- One M4x12mm pan head threading screw.
- Two claws.

7) Black Fuser Exit Guide
- Force it to go all the way down.

8) Inner Chute (Delivery Assembly)
- One M4x12mm pan head threading screw at the right side.
- One M4x12mm pan head threading screw w/spring at the left side.
- Pull the chute out the back.
- REINSTALLATION is less easy. The spring-loaded pinch rollers are a bit awkward. You have get the back end of the thing up and fully seated.

9) Top Cover
- Two M4x12mm pan head threading screws at the front.
- Two small claws at the front lip.
- Pull the cover forward to remove it.
- NOTE the two 'hooks' at the rear underside that must engage on reinstallation.
- NOTE that the blue 'Go' button is free to come away when the top cover is removed.

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