Lexmark T64X -- Catastrophic Fuser Roller Failure

When you can see daylight between a fuser's rollers, you know something is amiss.

Here's a view of it with the cover removed.

Metal fatigue, I guess. Where the reduced-diameter end of the roller meets the body of the roller, there's not a great deal of material. Here's a close-up of the broken-off end.

The rest of the fuser was ok. Sometimes, a broken fuser roller will cause the thermal fuse to go open.

This fuser had gotten a new pressure roller and pressure roller bearings only 1,300 pages ago. The coated roller had looked fine at the time, so there's no way you can see this coming.

I put a new roller in the fuser and it's good to go.

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