my wf-2960 is making a loud grinding noise when it prints, sounds like it's coming from the right side.

Diagnosis

This loud grinding noise emanating from the right side of the Epson WorkForce WF-2960 is typically caused by a failure in the paper feed gear assembly or a mechanical obstruction in the carriage return path. Specifically, the right side houses the primary drive gears and the tension springs for the paper feed rollers. When a small piece of torn paper, a staple, or a foreign object (like a coin or paperclip) falls into the gear train, it prevents the gears from interlocking smoothly, causing the plastic teeth to "skip" or grind against one another. Alternatively, the noise may be caused by the carriage rail lubrication drying out or a failure in the plastic gear that drives the print head carriage. If the noise occurs specifically as the print head moves from left to right, the issue is likely a carriage jam or a worn gear. If the noise occurs only when the printer is attempting to pull paper from the tray, the root cause is a stripped tooth on the feed roller gear or a foreign object lodged in the pickup rollers. You can confirm this by listening for the noise to start exactly when the "Paper Feed" motor engages versus when the "Carriage" motor moves.

How to Fix It

To resolve a grinding noise in the paper feed or carriage system, follow these precise steps:

1. Power down the printer completely and unplug the power cable from the wall outlet to prevent any electrical shorts or accidental carriage movement.
2. Remove all paper from the input tray and open the scanner unit to expose the interior of the machine.
3. Using a high-lumen flashlight, inspect the far right side of the printer. Look for "paper confetti"—tiny shreds of paper that often accumulate around the gear teeth. Use a pair of fine-tipped tweezers to remove any debris.
4. Locate the paper feed rollers at the rear/bottom. Gently rotate the rubber rollers by hand. If you feel a "catch" or a snap, there is a foreign object lodged in the gear assembly.
5. If the noise is related to the print head movement, slide the print head carriage manually to the center. Inspect the plastic timing strip (the clear translucent ribbon) for any ink smears or tears. Clean this strip with a dry, lint-free microfiber cloth; a dirty strip can cause the carriage to "hunt" for its position, leading to erratic movement and grinding.
6. Check the right-side gear assembly for any white plastic shavings. If you see shavings, a gear has stripped. Gently apply a tiny amount of white lithium grease to the gear teeth using a toothpick to reduce friction.
7. Reinsert the power cable and perform a "Print Head Alignment" from the Maintenance menu to ensure the carriage is tracking correctly without hitting the side walls.

If That Didn't Work

• Deep Clean the Paper Path: Use a can of compressed air to blow out the entire paper path from the rear. Often, a small piece of paper is lodged deep in the chassis where tweezers cannot reach, putting pressure on the drive gears and causing them to slip.
• Reset the Encoder Strip: If the grinding happens during carriage movement, the encoder strip may be misaligned. Carefully remove the small screw holding the strip on the right side, wipe it with 90% isopropyl alcohol, and re-seat it firmly. A slipping strip causes the motor to over-torque, creating a grinding sound.
• Replace the Pickup Roller Assembly: If the grinding is strictly during paper loading, the rubber tire on the pickup roller may have perished or detached from the plastic hub. You will need to replace the roller assembly (Part # WF2960-PR) to restore a smooth grip.
• Factory Reset the Hardware: In rare cases, a firmware glitch can cause the carriage to attempt to move past its physical limit. Perform a full factory reset via the settings menu to recalibrate the home position of the print head.

Heads Up

• Never use WD-40 or oil-based lubricants on the gears or the carriage rail; these attract dust and will eventually turn into a sticky paste that permanently jams the printer. Only use white lithium grease.
• Avoid using "cleaning" sheets or chemical solvents on the encoder strip, as these can strip the tiny markings the printer uses to track the print head's position.
• Always ensure you are using paper that meets the GSM specifications for the WF-2960; using overly thick cardstock can strip the plastic gears in the paper feed mechanism over time.
• If you hear a loud "clunk" followed by a "General Error" message on the screen, stop the printer immediately to avoid stripping the drive gears completely.