Remanufacturing the Xerox Phaser 3635MFP Toner Cartridge
First released in August 2008, the Xerox Phaser 3635MFP printers are based on a 35ppm, 1200dpi engine. The first page out is rated at under nine seconds, and the monthly duty cycle is up to 75,000 pages. Both model printers are print, copy, scan, fax, and e-mail capable.
These cartridges do not have a drum cover, and come new with a piece of heavy paper with foam glued to it taped around the cartridge.
There are both LY (5,000 pages) and HY (10,000 pages) cartridges available. Each version of cartridge has its own specific chip, but the cartridges themselves are identical. Methods to reset the OEM chips and/or new replacement chips should be available as you read this.
The chip covers are held in place by plastic rivets. To replace the chip, the rivets need to be cut off, holes carefully drilled, (not too deep or the cartridge will leak), and screws installed. This is definitely a cartridge where a reset box is the way to go.
The printers are Xerox Phaser 3635MFP/S and Xerox Phaser 3635MFP/X. The cartridges are LY cartridge 108R00793 (5,000 pages) and HY cartridge 108R00795 (10,000 pages).
Figure 1 shows the HY and LY cartridges, as you can see, they are identical so if you install the correct chip and toner load, you can easily make a LY a HY cartridge.
 Place the cartridge with the handle/supply chamber facing you. Remove the three screws on the right end cap. See Figure 2.
 Gently pry off plastic drum axle bushing. Keep this bushing with the appropriate end cap when removed. Each side is different. See Figure 3.
 On the top edge of the end cap, there is a plastic tab. Press in on the tab and remove the right end cap. See Figures 4 and 5.
 On the opposite side of the cartridge, remove the three screws on the left end cap. See Figure 6.
 Gently pry off plastic drum axle bushing. Keep this bushing with the appropriate end cap when removed. See Figure 7.
 On the top edge of the end cap, there is a plastic tab. Press in on the tab and remove the left end cap. See Figures 8 and 9.
 Lift off the roller cover. See Figure 10.
 Carefully pry up the side plastic tab to release the waste chamber. See Figure 11.
 Remove the waste chamber. See Figure 12.
 On the supply hopper, remove the fill plug and dump out any remaining toner. See Figure 13.
 Remove the developer roller drive gear; put a strip of tape across the remaining gears. They do not need to be removed; the tape will help keep them in place. See Figures 14 and 15.
 On the fill plug side, press in on the plastic tab and remove the spring/plastic bushing assembly. See Figures 16 and 17.
 Remove the developer roller. See Figure 18.
 Remove the two screws on the doctor blade. See Figure 19.
 Carefully pry up the doctor blade. This blade has a very tight fit; work it off carefully. See Figure 20.
 Clean out any remaining toner from the hopper.
 Clean the doctor blade and foam seals. It is too early to say exactly what chemical to use on the blade, but so far 99 percent isopropyl alcohol seems to work. See Figure 21.
 Replace the doctor blade and two screws. See Figure 22.
 Clean and install the developer roller, long shaft side to gear side first. See Figure 23.
 Snap the spring/plastic bushing assembly in place. Make sure the tail of the spring is set properly. See Figures 24 and 25.
 Install the drive gear on the developer roller. See Figure 26.
 Fill the hopper with 135g or 290g of Phaser 3635 toner. Check for leaks. See Figure 27.
 On the waste hopper, remove the E-ring from the drum axle. See Figure 28.
 Slide the drum axle out from the side opposite the E-ring. See Figure 29.
 Remove the OPC drum. See Figure 30.
 Slide the PCR to the non-contact side. Remove the PCR. See Figures 31 and 32.
 Remove the two screws and the wiper blade. See Figure 33.
 Clean out all the toner from the hopper.
It is interesting to note that on new cartridges, some toner is in the waste hopper. Apparently these cartridges are being tested before they are shipped, or the drum was lubricated with toner.
 Coat the new wiper blade with your preferred lubricant. Install the new wiper blade and two screws. The tail of the wiper blade should face up. See Figure 34.
 Clean the PCR with your preferred PCR cleaner.
WARNING: Do not clean the OEM PCR with alcohol, as this will remove the conductive coating from the roller. If the PCR is an aftermarket, follow the cleaning methods recommended by the manufacturer. If the PCR is an OEM, we recommend it be cleaned with your standard PCR cleaner.
 Clean the old conductive grease off the PCR shaft and contact. Replace with new. See Figure 35.
 Install the PCR by sliding the long shaft side through the non-contact side. Bring it back to fit into the contact side. See Figure 36.
 Coat the OPC drum with your preferred lubricant and install the drum. See Figure 37.
 Install the drum axle small drum gear side first. Make sure that the E-ring groove ends up on the small drum gear side. See Figures 38 and 39.
 Install the E-ring. See Figure 40.
 Install the waste hopper on to the supply chamber. Make sure that the tabs lock into place on the side wall. See Figure 41.
 Install the roller assembly. See Figure 42.
 Install the right side end cap and three screws. Make sure the top rear tab locks in place. See Figures 43 and 44.
 Press the drum axle bushing in place. Set it so the small tab is at the end of the groove; make sure it is fully seated. The two small bushings are different. Make sure you have the correct bushing for this side. See Figure 45.
 Remove the tape from the gears, and install the left side end cap and three screws. Make sure the top rear tab locks in place. See Figures 46 and 47.
 Press the drum axle bushing in place. Set it so the small tab is at the end of the groove; make sure it is fully seated. The two small bushings are different. Make sure you have the correct bushing for this side. See Figure 48.
 The chip is held in place by plastic rivets. It must be reset/replaced for the cartridge to work. Resetting is the easiest method, (See Figure 49) but it can be replaced by cutting the plastic rivets, drilling two holes, and setting two self-tapping screws in place. See Figure 50.
Printing Test Pages:
As these machines are copiers, the easiest way is to just make a copy of a suitable test page.
Repetitive Defect chart:
OPC drum — 75.5mm
Supply roller — 44.9mm
PCR — 37.7mm
Developer roller — 35.2mm
This article originally appeared in the November 2008 issue of Recharger.