a) The pickup solenoids become sticky with age. See this post for more information, and a repair method
b) A roller clutch on the paper feed assembly is prone to gum up and slip. See this post for service information.
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Proceed as follows:
1) Cartridge
2) Tray 2
3) Tray 2 Rear End Cover (if present)
- Two claws high up, accessible through small rectangular openings.
4) Back Door
- Open it and pry at the right side hinge to free the door.
5) Fuser
- Two lock levers.
6) Rear Right Side Cover (Formatter Cover)
- Tug it rearward to remove it.
7) Control Panel Overlay
- Pry at its right side lip to free two small claws.
8) Control Panel
- There's a claw at either side near the front. Nudge them with a small screwdriver to free them.
- One cable connection.
9) Top Cover
- Two M4x12mm bright pan head threading screws at the back.
- Two M4x12mm bright pan head threading screws under the toner cartridge access door.
- Cartridge engagement arm -- free its upper end.
- Pry at the right front to free the right front corner.
- Tug the front of the cover up forcefully to free it.
- NOTE: The door's hinges are easily separated to facilitate washing the door and cover.
10) Front Right side Cover
- One claw at the top.
- NOTE: MIND the switch rocker/rod engagement when reinstalling this cover.
11) Left Side Cover
- Lift it slightly and tip it away.
12) Tray 1 Door
- Pry gently to free the inner platform from its ways.
- Slide the door rightward off its hinges.
13) Tray 1 Platform w/Sensor Arm Cover and Torsion Spring
- Disengage the torsion spring.
- Tug forcefully on the sensor arm cover to pop it off the pickup shaft.
- Lower the platform a bit and it can be slipped off its left side hinge pin.
14) Two Extended Head M4 Screws near the Front
- The left side screw is visible by the yellow cable for Tray 1's paper-out sensor.
- The right side screw's head is just below and to the right of the envelope feeder connector.
15) Tray 1 Pickup Assembly w/Left Side Cartridge Guide
- One in-line cable connection for the pickup solenoid.
- One cable connection for the paper-out sensor.
- Five M4x12mm bright pan head threading screws in front. Three of them are in deep wells.
- INSPECT the pickup solenoid for stickiness.
16) Paper Feed Assembly
- One in-line cable connection.
- Two M4x12mm bright pan head threading screws. NOTE that these are in the upper holes of the brackets. The two lower holes are where two of the Tray 1 pickup assembly's screws go.
17) Cover-Open Switch Bracket
- One M3x6mm bright pan head screw w/captive star washer at blue ground wire terminal.
- One M4x12mm bright pan head threading screw forward of and below the previous screw.
- Free the bracket and let it dangle by the side of the machine.
18) Registration Assembly
- One M3x6mm bright pan head screw w/captive star washer at the extreme right.
- NOTE. There is an M3 hex head screw forward of and to the left of the previous screw. DO NOT loosen it.
- Five M4x12mm bright pan head threading screws.
- Overhaul per this post.
19) Pre-Transfer Ground Plate
- Tip up its right side end and slip it out.
20) Delivery Assembly
- The left side white bearing unhooks easily and lifts out.
- The right side bronze bearing has a lever on it. Swing the lever up to vertical and the unit can be lifted out.
- Overhaul per this post. (Scroll down to "To dismantle...".)
21) Printhead
- Three cable connections.
- One M3x8mm pan head threading screw at blue ground wire terminal.
- Four M4x12mm bright pan head threading screws.
- DO NOT DISTURB the hex recess head screw at the centre rear. It was factory-adjusted for optical skew correction.
22) Formatter Cage
- One M3x6mm bright washerhead screw at an upper, forward-pointing tab.
- One M4x10mm black pan head threading screw at a lower, forward-pointing tab.
- Tug the cage rearward to disconnect it.
23) Right Side Engine-to-Tray Module Attachment
- Two M3x6mm bright pan head screws w/captive star washers.
24) Fourteen-Conductor Cable Connector
- Unplug it and free it from its hooks.
25) One M4x12mm Bright Pan Head Threading Screw
- It's at the left side, just below and behind the lower rear corner of the fan.
26) Engine Chassis
- It's free to be lifted off the paper tray module.
- Blow out the chassis w/compressed air.
27) Engine Controller PCA
- NOTE: This part needn't be removed, but it should be unfastened so the PCA and its environs can be blown out with compressed air.
- Switch rod. Disengage its rear end from the switch and move the rod aside.
- Three cable connections at the fan side of the PCA.
- Four M4x12mm bright pan head threading screws.
- Three M3x6mm bright pan head screws w/captive washers.
28) Tray 2 Top Cover
- Two M3x6mm black pan head screws.
- Four M4x10mm black pan head threading screws.
29) Tray 2 Pickup Assembly
- One two-conductor cable connection. Free the black cable from its restraints.
- Lift the unit out.
- Clean/replace rollers A/R.
- INSPECT the pickup solenoid for stickiness.
30) PCA Cover
- Two claws at the top edge.
31) PCA P/N RG5-2673
- Two cable connections.
- Two claws.
- Apply WD-40 to the pushbutton switches and actuate them many times. Blow them out w/compressed air.
32) Blow out and clean the base A/R.
33) Reassemble the tray module.
34) Reinstall the chassis on the tray module.
35) Reassemble from step '25)'.
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