I have a Phaser 6130 (HAT046224) that was working fine with very low page count on it until it started making a clicking sound like gears slipping when trying to print and simultaneously stopped printing. Being a DIY kind of guy, I got a manual for the printer and started to troubleshoot. Here's what I've found:
there are no error messages shown
In service mode:
the ESS diagnostics (All Test) passes (Check OK)
the sensor tests all pass
the clicking sound occurs during the Main Motor tests (Full1, Full2, and Half)
the Sub Motor tests all pass (in Full1, Full2, and Half, the clicking sound doesn't occur)
the K Mode Solenoid test passes
the Tray Feed Solenoid (Half) test does not seem to pass since the Feed Roller doesn’t make a half-turn (but I hear the solenoid click at the end of the test while the clicking sound occurs throughout the test - because the Main Motor is running)
the Tray Feed Solenoid (Init) test does not seem to pass since the Feed Roller doesn’t do anything (in this test, I do not hear the solenoid click at the end of the test, but the clicking sound occurs throughout the test because the Main Motor is running)
the Fan (High) and Fan (Low) both pass
the Toner Motor tests all pass
the Regi Clutch test passes (even though the clicking sound occurs because the Main Motor is running)
the Tray Feed Solenoid (Auto) test appears to pass since the solenoid clicks closed and then opens
the Drum Erase Lamp tests both pass
The clicking noise seemed to emanate from the Paper Feed Drive assembly, so I pulled it off the unit and with it removed (even still connected), the Main Motor tests no longer created the clicking noise. At this point, I concluded that the Feed Drive assembly was suspect, especially since one of the gears had a segment missing (Gear C). It seemed that when the drive spun one way, the Color Mode Switching Solenoid would catch Gear C and keep it from engaging. If the drive spun the other way, Gear C became the clicking noise as Gear P4-2 sat in the open segment of Gear C. Based on that observation, I decided to replace the Feed Drive assembly (PN 007K94706). When it arrived, I was surprised to see the new Feed Drive assembly looked the same as the one I had, but I put it in and found that I still had the clicking noise.
Somewhere in all of this, I did something while things were running and broke the Feed Gear (another one with segments missing), so I had to replace that as well (PN 675K54150).
So now you can see that I’ve clearly missed the real problem, but I don’t know what it is. I suspect I didn’t give enough weight to the fact that the Feed Roller doesn’t do anything during the Tray Feed Solenoid (Half/Init) tests (mainly because the Tray Feed Solenoid (Auto) test seemed to do something), but I’m stumped now. I sure would appreciate any thoughts anyone has regarding what could be the root cause of this problem and what I should do next. Thanks!