Sensor Toggle Repairs

It's often possible to repair broken sensor toggles with solid copper wire and CA adhesive. Here's a repair made to a narrow-media sensor from a Lexmark T630 fuser.

18 AWG (0.0403" diameter) wire is substantial enough, yet relatively easy to form. Once you have the wire formed and in place, clean the item thoroughly with methyl hydrate, let it dry and apply CA adhesive so it wicks in everywhere between the copper wire and the plastic toggle. Take great care that the glue doesn't get away from you and foul the torsion spring or pivots. Leave the thing undisturbed for awhile for the glue to thoroughly harden.

On reinstalling the sensor, check that your repair's length/shape is ok and tweak it A/R. Here's a view of this sensor back in the machine.

I've done enough of these that I've seen machines return to the shop after considerable service with one of these repairs; this repair method appears to hold up fine.

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