Lexmark X544 -- Fuser Removal

Fuser removal in the X544 is not pleasant. You'll need a spring hook. Proceed as follows:

1) Paper Tray

2) Front Door Open

3) Flatbed Scanner
- Raise it. There's a latch-button at the right side with a 'toner' symbol on it. Squeeze that and lift firmly. The flatbed will lift and latch. Squeeze the button again when you need to unlatch and lower the flatbed.

4) Right Side Cover
- Press two green buttons. The cover swings down and comes away from its hinges easily.

5) Left Side Cover
- One M3.5x6mm pan head threading screw in centre of handgrip.
- One M3.5x6mm pan head threading screw below line cord receptacle.
- One M3x6mm washerhead screw above and inboard of line cord receptacle.
- One M3.5x6mm pan head threading screw by upper outboard corner of fan.
- Flex the cover outward below and behind the on/off switch to disengage a tab at the bottom front of the cover. The cover can then be fully eased off.

6) Fuser Power Cable
- Disconnect blue and white cable from rear of power supply at left side of printer. Free the cable from its restraint.

7) Fuser Frame Screw
- One M3.5x9mm pan head screw w/captive washer directly above fuser motor.

8) Thermistor Cables
- Two small two-conductor cable connections at right front of fuser; one black, one white.

9) Timing Belt
- CAUTION: Try to disturb this belt as little as possible when dealing with it. Should it get dislodged from its path inside the machine, you could be in for an ordeal. NOTE that it's toothed on both sides.
- It's at the extreme upper left of the fuser. Dislodge it from its pulley; you'll have to pry it off with a small screwdriver.
- AT REINSTALLATION, you'll need a spring hook to get the belt back in place.

10) Retention Springs
- There are two extension springs securing the upper ends of the fuser's frame. Unhook them.
- AT REASSEMBLY, make sure the springs are perched upright so they can be hooked for reattachment.

11) Exit Sensor
- Tip the fuser outward. At the sensor's underside there's a thin black retention plate. Pry that off and the sensor can be freed from its cut-out in the sheet metal.
- Free the sensor's cabling from the fuser's frame.

12) Fuser
- Tip the fuser out fully, slide it leftward a bit and it can be lifted off the rod that it pivots on (note the flats). Coax the blue and white power cable out along with the fuser.
- NOTE that at reassembly, the blue and white power cable goes inboard of the fuser's pivot rod.

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