HP LaserJet 40X0 -- Tray 1 Pickup Assembly Replacement

Pickup roller and separation pad replacement are usually all the maintenance required on the tray 1 pickup assembly. It's possible for the solenoid to become sticky, resulting in mistimed extra pickup cycles. This post shows how to deal with that problem without having to replace anything. When you see the pickup roller hesitate as it's cycling, you know that its wrap-spring clutch is slipping. The clutch is an ultra-cheap one with plastic hubs; there's no servicing it, and service replacements can't be had. You have to replace the entire pickup assembly.

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The Tray 1 Pickup Assembly's P/N is RG5-2655. Proceed as follows:

1) Cartridge

2) Tray 2

3) Back Door
- Open it. It needn't be removed.

4) Rear Right Side Cover
- Tug it rearward to remove it.

5) Control Panel Overlay
- Pry at its right side lip to free two small claws.

6) Control Panel
- Pry up its front edge and two claws will let go. If the claws don't let go readily, you may need to coax them individually; they're down at either side near the front.
- One cable connection.

7) 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.

8) Front Right Side Cover
- One claw at the top.
- AT REINSTALLATION, MIND the on/off rocker's engagement with the switch linkage rod.

9) Left Side Cover
- One claw high up rear of centre.

10) Tray 1 Door
- Pry the inner platform's ways aside gently to free the platform.
- Slide the door rightward off its hinges.

11) Tray 1 Platform w/Sensor Arm Cover and Torsion Spring
- Torsion spring. (Not present on early machines. 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.

12) 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.

13) 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.

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