Lexmark T64X -- MP Feeder w/Snags

We ran into a T640 giving frequent jams from the MP Feeder. The cause turned out to be a factory defect in the moulding of the lower deflector. Here's a photograph of the flaw.



It's not a great photo, but note the corner of that nearest rib -- it extends vertically a tiny bit above the leading edge of the upward-curving ramp portion of the rib. All the ribs were like that, and jammed sheets showed evidence of snagging at the position of the second rib from the right.

Cutting off the tiny upward projections with a sharp utility knife, and filing a bit to round over the corners fixed it. Here's a view of the part after cutting and filing.


I imagine this flaw results from misaligned moulding equipment. There are probably many such flawed MP Feeder lower deflectors out there.

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