my brother printer is making a loud grinding or clicking noise when it tries to pick up paper

Diagnosis

The loud grinding or clicking noise in the Brother DCP-L2640DW is typically caused by a failure in the paper feed mechanism, specifically when the pickup roller fails to grab the paper. When the rubber roller surface becomes "glazed"—smooth and shiny due to paper dust and wear—it loses the friction necessary to pull a sheet from the tray. The motor continues to spin the drive gear, but because the roller is slipping, the gears may skip or "chatter," creating that rhythmic clicking or grinding sound. In some cases, this is exacerbated by a misalignment of the paper guides or a foreign object (like a staple or small scrap of paper) lodged in the feed slot. If the noise is a sharp, metallic grinding, it often indicates that the pickup roller assembly has shifted off its axis or a plastic gear tooth has sheared, preventing the roller from engaging the paper stack. You can confirm this by attempting a "Manual Feed" print; if the printer pulls paper silently from the manual slot but grinds when using the main tray, the issue is isolated to the tray pickup assembly.

How to Fix It

Follow these steps to restore grip to the rollers and clear the feed path:

1. Power off the printer and disconnect the power cable from the wall outlet to prevent electrical shock or accidental printing.
2. Remove the paper tray completely from the machine. Set it aside on a flat surface.
3. Open the front cover of the printer and remove the toner cartridge and drum unit assembly to provide a clear view of the internal chassis.
4. Locate the pickup rollers at the bottom of the feed area (these are the rubber-coated wheels that contact the paper).
5. Dampen a lint-free, non-abrasive cloth with warm distilled water. Wring it out thoroughly so it is damp, not dripping. Avoid using isopropyl alcohol, as it strips the rubber's elasticity and accelerates wear.
6. Gently rotate the roller by hand while wiping the rubber surface. Focus on removing the white, powdery paper dust and the "glaze" from the circumference of the roller.
7. Use a cotton swab dampened with water to clean the small separation pad (the small rubber piece that prevents multiple sheets from feeding).
8. Dry the rollers with a clean, dry cloth.
9. Reinstall the drum and toner unit, slide the paper tray back in, and ensure the paper guides are snug against the paper stack without bending the sheets.
10. Reconnect power and run a test print.

If That Didn't Work

• Replace the Pickup Roller Kit: If cleaning doesn't stop the noise, the rubber has likely hardened beyond recovery. Purchase a replacement pickup roller kit (Part No: DK2210). Remove the old roller by releasing the plastic retaining clip on the side of the gear assembly and snap the new roller into place.
• Inspect the Feed Gear: Check for a broken tooth on the drive gear located behind the pickup roller. If you see plastic shards in the gear housing, the gear assembly needs replacement. Use a vacuum or compressed air to clear out the debris before installing a new gear.
• Check for Obstructions: Use a flashlight to inspect the gap between the tray slot and the internal rollers. Even a tiny piece of torn paper from a previous jam can cause the roller to slip and the motor to grind. Use a pair of long-reach tweezers to pull out any debris.
• Reset the Paper Settings: Ensure the printer software is set to the correct paper type (e.g., "Plain Paper" vs "Recycled"). If the printer thinks it is feeding heavy cardstock, it may adjust the timing of the rollers, which can lead to clicking if the paper is actually thin.

Heads Up

• Always use high-quality, 20lb bond paper. Using overly thin or extremely textured paper increases the amount of dust deposited on the rollers, leading to more frequent slipping.
• Avoid overfilling the paper tray. Filling the tray beyond the maximum mark puts undue pressure on the pickup mechanism and can cause the rollers to wear unevenly.
• Fan your paper stack before loading it into the tray to break the static bond between sheets, which reduces the strain on the pickup motor.
• Perform a "Roller Clean" every 2,000 to 5,000 pages to prevent the glaze from building up, extending the life of the rubber components.