Brother MFC-8440 Installation instructions

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
4-4
3.3 Paper Tray
(1) Close the front cover and pull out the paper tray.
(2) Remove the paper from the paper tray.
Fig. 4-3
(3) Remove the pad holder and the separation pad spring from the paper tray.
Fig. 4-4
Front cover
Paper tray
Pad holder
Separation pad spring
Paper tray
1
2

MFC-8440/8840D/8840DN, DCP-8040/8045D/8045DN
SERVICE MANUAL
4-5
NOTE:
When replacing/re-assembling the pad holder ZL2 ASSY, remove the old grease and apply a
suitable amount of grease referring to the figure below;
Fig. 4-5
(4) Remove the four bind B M4x12 Taptite screws, and then remove the paper tray front
cover.
Fig. 4-6
Paper tray
Paper pick-up roller
Grease: Molykote PG-662
(4 mm dia.ball)
Taptite, bind B M4x12
Taptite, bind B
M4x12
Paper tray front cover
Paper tray
Hook
Hook

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
4-6
(5) Remove the two cup B M3x10 Taptite screws, and then remove the paper tray cover.
Fig. 4-7
(6) Remove the pressure roller holder.
Fig. 4-8
Paper tray
Taptite, cup
B M3x10
Paper tray cover
Flat screwdriver
Pressure roller holder
Paper tray
Taptite, cup B M3x10

MFC-8440/8840D/8840DN, DCP-8040/8045D/8045DN
SERVICE MANUAL
4-7
(7) Remove the pressure roller collar.
(8) Remove the pressure roller shaft.
Fig. 4-9
(9) Remove the scratch spongy holder ASSY from the pressure roller holder.
(10) Remove the two scratch spongy springs.
(11) Remove the scratch spongy from the scratch spongy holder ASSY.
Fig. 4-10
Pressure roller shaft
Pressure roller holder ASSY
Scratch spongy
Scratch spongy holder ASSY
Pressure roller holder
Scratch spongy springs
1
2
Pressure roller collar

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
4-8
(12) Remove the two cup M2.6x5 Taptite screws.
(13) Release the lock lever, and then unhook the catches of the two side guide racks.
Fig. 4-11
(14) Remove the side guides right and left from the paper tray.
Fig. 4-12
Taptite, cup M2.6x5
Taptite, cup M2.6x5
Side guide rack
Lock lever
Paper tray
Catches
Paper tray
Side guide L
Side guide R
Side guide L
Side guide L
2
2
1
2
1
2
1
Side guide rack

MFC-8440/8840D/8840DN, DCP-8040/8045D/8045DN
SERVICE MANUAL
4-9
(15) Unhook the two catches (A) of the pressure plate while pulling the plastic frame outwards,
then unhook the other two catches (B) of the plate while pulling the plastic frame outwards
to remove the pressure plate ASSY.
Fig. 4-13
(16) Unhook the pressure plate spring from the plastic hook to remove the two pressure plate
springs.
Fig. 4-14
Pressure plate ASSY
Plastic frame
Catches (A)
Paper tray
Paper tray
Pressure plate spring
Pressure plate spring
Catch (B)
Hook

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
4-10
NOTE:
When re-assembling the pressure plate ASSY, ensure that the paper indicator arm is under the
pressure plate.
!
CAUTION:
When unhooking the catches to remove the pressure plate, do not bend the pressure plate,
gently ease the plastic cover. If the pressure plate is deformed, paper feeding problems may
occur.
(17) Remove the herical extension spring.
(18) Remove the lock lever.
Fig. 4-15
NOTE:
When re-assembling the lock lever, insert it upwards from underneath the cassette and rotate
it until the two catches lock into place.
Herical extension spring
Lock lever
1
2
3
Paper tray
Paper tray
Lock lever

MFC-8440/8840D/8840DN, DCP-8040/8045D/8045DN
SERVICE MANUAL
4-11
(19) Remove the cup B M3x8 Taptite screw, and then remove the side guide gear and the
friction spring.
(20) Remove the two side guide racks.
Fig. 4-16
(21) Remove the paper indicator.
Fig. 4-17
Side guide rack
Side guide rack
Paper tray
Paper indicator
Taptite, cup B M3x8
Side guide gear
Friction spring
2
1
1

CHAPTER 4 DISASSEMBLY AND RE-ASSEMBLY
4-12
NOTE:
• When re-assembling the side guide racks, they should both be aligned so that the wide end
of the racks are in line with the inside edge of the paper guide release slots in the tray
before refitting the spring and gear.
• When replacing/re-assembling the paper cassette, remove the old grease and apply a
suitable amount of grease onto both sides of the paper tray referring to the figure below;
Fig. 4-18
(22) Remove the pan B M3x8 Taptite screw, and then remove the tray lock lever.
(23) Unhook the four hooks to remove the paper tray rear from the paper tray.
Fig. 4-19
Taptite, pan B M3x8
Tray lock lever
Paper tray
Hook
Paper tray rear
Paper tray
Grease: Molykote PG-662
(2 mm dia. ball)
Grease: Molykote PG-662
(2 mm dia. ball)
Hooks
Hook
1
1
2
2
3

MFC-8440/8840D/8840DN, DCP-8040/8045D/8045DN
SERVICE MANUAL
4-13
(24) Remove the paper rear guide.
Fig. 4-20
Paper tray
Paper rear guide
2
1
1