The following procedure removes a couple of items that it's not absolutely necessary to remove, but removing them makes the machine less awkward to work with -- the job goes more smoothly. It's quite a teardown to get at the thing, but it's straightforward. Proceed as follows:
1) Cartridge
2) Tray 2
3) Tray 2 Rear End Cover, if present
4) Fuser End Caps
- Tug their lower edges out and up.
5) Back Door
- Open it and pry at the right side hinge to free the door.
6) Fuser
- Two captive screws.
7) Rear Right Side Cover (Formatter Cover)
- Tug it rearward to remove it.
8) Control Panel Overlay
- Pry at its right side lip to free two small claws.
9) Control Panel
- Pry up its front edge and two claws will let go.
- One cable connection.
10) 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.
11) Front Right Side Cover
- One claw at the top.
12) Left Side Cover
- One claw high up rear of centre.
13) Tray 1 Door
- Pry gently to free the inner platform from its ways.
- Slide the door rightward off its hinges.
14) Tray 1 Platform w/Sensor Arm Cover and Torsion Spring
- Torsion spring. Later machines have a torsion spring associated with the right side hinge. Free it from the underside of the platform.
- Tug forcefully on the sensor arm cover to pop it off the pickup shaft.
15) Two Black Extended Head Screws near the Front
- The left side screw is visible by the violet cable for Tray 1's paper-out sensor.
- The right side screw is concealed under the envelope feeder's connector cover. Open the cover and you'll see the screw's head.
16) 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 black pan head threading screws in front. Four of them are in deep wells.
17) Paper Feed Assembly
- One in-line cable connection.
- Two M4x10mm black 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.
18) Cover-Open Switch Bracket
- Three cable connections.
- One M3x6mm bright pan head screw w/captive star washer at blue ground wire terminal.
- One M4x10mm black pan head threading screw forward of and below the previous screw.
19) Registration Assembly
- One M3x6mm bright pan head screw w/captive star washer at the extreme right.
- NOTE. There is another M3 screw forward of and to the left of the previous screw. DO NOT loosen it.
- Five M4x10mm black pan head threading screws.
20) Pre-Transfer Ground Plate
- Tip it up at the right and slip it out rightward.
21) Transfer Roller
- Hook it at the ends and tug upward to pop it out of its bearings.
22) 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.
23) Formatter Cage
- Four M3x6mm bright washerhead screws. (Early machines had a fifth screw at the top.)
- Tug the cage rearward to disconnect it.
24) Formatter Cage Receiver (Sheet Metal)
- Four M4x10mm black pan head threading screws.
- Three M3x6mm bright pan head screws w/captive star washers or washerhead screws.
25) Fourteen-Conductor Cable Connector
- Unplug it and free it from its hook.
26) One M4x10mm Black Pan Head Threading Screw
- It's at the left side, just below and behind the lower rear corner of the fan.
27) Engine Chassis
- It's free to be lifted off the paper tray module.
28) Engine Controller PCA
- One cable connection near the fan.
- Switch Rod -- unhook it at the switch and free its front end from its restraint.
- One ground connection -- the torsion spring end for the drum ground. Free its lower end from a notch in the PCA's sheet metal cover.
- Three indicated M3x6mm dark pan head screws w/captive star washers.
- Four indicated black M4x10mm pan head threading screws. NOTE that there's a prominent
bright screw that remains in place.
- Tip up the fan side of the PCA.
- One fuser power cable connection.
- Nine conventional cable connections.
- One ribbon cable connection.
29) Rectangular Cable Cover at Front Right
- One claw at the right side near the rear.
- Two long-reach claws near the middle.
- One claw at the front -- it's visible and accessible from above.
30) Formatter Cable/Connector Assembly
- One M4x10mm black pan head threading screw.
- NOTE the tab at the rear end of the rectangular underside piece. At reassembly, get that tab in place first, prior to positioning and fastening the main, upper part of the assembly.
31) Main Drive Assembly w/Wiring Harness
- Stand the chassis on its left side.
- Seven M4x10mm black pan head threading screws.
- Lift the assembly straight out.
32) Paper Feed Guide Assembly
- Two M4x10mm black pan head threading screws.
- Tug the assembly forward slightly to free three small studs at its rear.
- NOTE the ground continuity leaf at the right rear of the assembly. It contacts the sheet metal tab's upper surface.
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