How to Fix a Broken Printer Hinge and Door Sensor (HP Officejet J6488 All-in-One - Maybe Helpful for Other Printers Too)




Hello inventors, this is my first instructable. Hope that this proves helpful for some people like me, who broke their hp printer's door hinge and made it piece of plastic of no use.
This guides you how to fix a broken printer door hinge and make the door sensor work.
This is a very known bug in HP officejet printers. When you Open the door in order to change the cartridges or remove a jammed paper after a long time since the door was lifted, the hinges gets stuck and cracks. And that;s when you screwed it up.There are no repairs available with HP aswell. They'll charge your pockets on fire if you get the upper section replaced, no matter your product is under warranty or not.
So, if you have not yet cracked the door hinges, put some silicon oil or any other suitable lubricant between the hinges.
later we'll also fix a broken door sensor trigger, in this instructable.
OK, now we need the following things:

1. 3 Small size door hinges - refer image
2. Epoxy Putty
3. Industrial glue
4. Duck tape
5. Hexalobular star screw driver(maybe different headers for other models/printers
6. Screw bridge or any alternative similar shaped piece of plastic for the broken door sensor trigger

Here we go.......

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Step 1: Unscrew and Remove the Broken Hinges

Unscrew all the screws and remove all the plastic covers and hinges as we dont need this mechanism anymore. The upper and lower part of hinges are clip attached.
you need a Hexalobular star screw header for HP printers.
There is a plastic cover where inside are the two screws of the upper section of the hinge , then two screws on the other side of the door.
Remove them all. Make sure you dont damage the wires connecting the upper section.

Step 2: Stick or Screw the New Hinges

Take the new hinges, place them right over the removed hinges such that there is no problem in its axial movement. all the hinges must be parallel to each other. Mark points to correctly stick or screw the hinges.(you may drill new holes to attach them using screw or nuts, here we'll stick them to the base instead)
Place the third hinge right in the middle of the two hinges, just to distribute loads. You can add more hinges.
Put industrial glue on the back side of all three hinges and place it where you marked the points........
tilt the printer front side down, just to make sure the hinges dont change positions while the glue dry. Put duck tapes for double safety. Its important or the door may never open properly.
leave it for 4-5 hours.
As soon as it dries, put epoxy putty on the sections of hinges from inside to make the hold stronger.

Step 3: Fixing the Broken Door Sensor

My House was taking heavy fire when a bunch of kids made my house a warfare in a family gathering. They cranked the printer doors up and bent the door sensor trigger for a reason nobody will ever get to know.Since then i used piece of paper inside the sensor trigger to use my printer.
but then later i got time to get a proper fix because changing cartridges became hell of a job.
Find a proper replacement. a screw bridge or a shaped piece of aluminium sheet is recommended.
use epoxy glue to stick it right at the place of the broken trigger. Make sure it gets into the sensor hole properly and there is no difficulty in closing the door.

Step 4: Precautions and Some Cleaning

Make sure you don't:- the door more than 90' or you'll stretch off the connecting wires to the scanner.
2.stick the hinge joints.
3.stick the hinges incorrectly.
3.put a lot of glue on the sensor trigger alternative and stick the doors. Let it dry before you close the door.
4.mess up any of the internal circuitry or wires of the printer.
5.get too busy in family gatherings and allow terrorists to blow your things up.

Step 5: We'r Done, Congratulations!

We'r done. now you can easily clean or change printer cartridges and fix jammed paper...
I hope this was helpful....

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13 Discussions

Lisa Gershion77

Question 1 year ago on Step 5

Left my very nice printer outside in my parents’ garage for 2 years while I was overseas. Of course when I came back the ink was all clogged inside.


1 year ago

Is it possible to get a Utube video of the the door fixing on the printer ? Thanks.


1 year ago

I got only two screws (left and right). Please what I am doing wrong to fix the printer’s door.
Shankar Mistry


2 years ago

Thanks for the fix - had the same problem as well - model J6480 - left hinge broke. Used a variation of your fix - simply removed the top (lid) hinge (undo the 4 hex screws holding this hinge in place) that enabled the lid to fit flat and close the door sensor so the printer can be used. Instead of fixing a metal hinge just used a strip of duct tape to hold the lid in place and to effectively hinge the joint - less secure than the metal hinge but quick/easy fix. Use black tape - looks better.


2 years ago

Just busted this printer's hinges tonight..thought she was a goner! I'm so excited that I can fix it as I really need it, and REALLY can't afford to replace her right now. you ROCK!!!


3 years ago

This is brilliant, I had everything I needed lying around the shop. The printer has proven to be a workhorse, reliable, easy to deal with. I would hate to throw it away for the little bit that went wrong.


3 years ago

just want to add some suggestions: after your done fixing this printer with the hinges. Put a short string on both sides of the cover, just measure the length of the string base on how far the top cover will open as not to damage the ribbon cable when you open it to change cartridge or do maintenance ex. paper jam


3 years ago

Awesome just save me a lot of cash in a buying a new printer. Very helpful indeed, added it in my collection and favorited. Just one question can i used a screw on the hinges plus glue it. Is there any ribbon cable or wires that will get damage? LIFESAVER...YOU ROCK DUDE!


4 years ago

Life Saver! Thank you so much!

Yahoooeeee! I can't believe I found this on a whim Google search after I snapped my hinge on this exact printer! Sadly I have already beat on it, twisted it and what not and have exposed the flat white plastic cable cords?? to the scanner. Think all hope is lost?

2 replies

I'd say probably not, guessing you've already tossed it but if you haven't there are just a couple of ribbon cables providing those aren't damaged you maybe able to salvage them.... give it a shot, you really have nothing to lose.

Thanks K - I actually did save it and have been using it without a hich. The cables were fine once I got them stuffed back in, it was just the hinge. Thanks again :-)