The bar and gear cover will not go back on. The

Intro: This is a fairly difficult task, so really make sure you want to do this first. Factor in the cost of the transfer belt(maybe $25 dollars off of Ebay??) and it's not such a good deal. Anyway, for the DIYer diehards, keep reading.Necessary equipment:1. Number 2 philips screwdriver and a really small flathead screwdriver2. Disposable gloves3. 12 inch strip of cardboard or plastic4. Vacuum cleaner5. Spring hook removal tool (can made a simple one with a pair of pliers and a paper clip)
Disassembly: 1. Place the transfer belt assembly down on a table, so that the paper belt drive is on your right side. Remove the paper drive belt assembly by removing the three bright screws that hold it in place.
2. Turn the whole thing over and remove the rubber roller at the bottom. This is done by first carefully remove the spring that hold one of the plastic end in place. Choose the end that has the metal grounding tab on it. Be really careful to not damage the plastic tabs that hold the spring ends. The grounding tab must be pulled up slightly in order to go over a plastic nub before you can slide the plastic end off. Don't pull the metal too hard, or it will be permanently deformed. Place these parts to one side. The metal ends of the rubber roller have a little bit of grease on it, so just leave it there.
3. Flip the transfer belt assembly back over and on the right side, there is a protruding piece of plastic that has an electrical connector attached to the end of it. It's held in place by two black screws. Remove those two screws and the assembly will now hang there by the wires.
4. Remove the top plastic piece (covers the green release lever). There are four black screws that hold this in, two screws on each side. The part will dangle because it is connected by the same wires that connect to the piece in step 3.
5. With the removal of the part in step 4, the green release lever assembly is completely exposed. There are two springs (one on each side) that pull the plastic ends of the release assembly to its normal position. These springs need to be carefully removed. The spring hook removal tool is handy here. Finally, there is a holding tab on each of these end pieces, which needs to be carefully pulled up about 2 mm or so and then the end will slide off the metal bar. Don't lift up on the tabs too much or they will break off.
6. There are 4 bright screws that hold the excess toner tank. (This is the big piece of plastic with ribs, that the paper belt drive assembly was attached to. This tank will now come off, since the part in step 4 has been removed. The tank will be full of excess toner, so have the vacuum cleaner handle to clean up the mess. Shake the toner out into a garbage can.
7. Underneath the excess toner tank is a scraper/cleaner bar. Two bright screws hold the bar in place. Take care to not deform the metal grounding tab that grounds the bar during operation.
8. Take the left side plastic panel off now. There are 4 black screws that hold it in place. It should come free. If something is holding it in place, then you probably skipped step 5 and didn't remove the green release level assembly yet.
9. There is a round rod which will come loose as soon as the left side panel is removed. This round bar works with the scraper to clean the excess toner from the transfer belt. Note that one end of the round bar has been machined to have a smaller diameter. That end goes toward the left side plastic panel. Put the round rod aside for now.
10. There are two round rollers on the top and bottom of the transfer belt assembly that are used to stretch the belt. The bigger round roller is spring loaded to provide the tension needed to keep the belt flat during operation. Using a small flathead screwdriver, carefully remove the compression spring (hidden under the left side plastic panel earlier) so as to release the tension from the belt.
11. Put your gloves on now, because in the following steps, foam rollers will be exposed and it's best not to get body oils on them.
12. There is still tension on the belt because there's a compression spring on the other end of the big round roller, but that's okay. Now, press on the plastic end piece that holds onto the roller to completely release all tension on the belt. The belt will now slide off. It won't come off easily since it's a tight fit. Just work at it and it will come out. Note, one side of the belt has a rubber track inside of it. That's the orientation that the new belt must go back in on.
13. With the old belt removed, the inside of the transfer belt assembly is now completely exposed. Vacuum the excess toner dust.
Reassembly:
14. Note where the round bar that pressed against the scraper should be. There are pieces of plastic protruding here which will damage the new transfer belt as it is being put into place. Cover these protruding points with a strip of cardboard, 12 inches long and about 1-2inches in width.
15. Now, holding everything in your lap and with the right side down, press on the end piece of the big roller as before, so that it is possible to slide the new belt down into place. Take your time, and it will finally get into place. Try your best to not fold the transfer belt material in any way. You will know the belt is in place when the rubber inside track goes into the groove of the black plastic roller at the near end of the big roller.
16. Put the compression spring that pushed the end of the big roller back into place.
17. Slide the round bar approximately now where it should go. Remove the protective strip and position and push the bar end into the brass bushing. Remember, the machined end of this round bar should be aligned so that it clears the inner rubber track of the belt. I put a drop of light machine oil on the brass bushing, but I don't know if was really necessary.
18. Carefully put the left side panel back into place, noting that the smaller roller end and the round bar have to aligned properly before the panel will slide into place. Again, I put one drop of light machine oil on each brass bushing just before putting it all together. Four black screws are used to hold the panel in place.
19. Put the scraper bar back into place using two of the bright screws. Note, the metal tab on one end should be pressing against the bar, making electrical contact when it is in properly.
20. Put the excess toner tank back into place, using4 black screws.
21. Return the green release lever assembly pieces back into place, basically performing the earlier steps in reverse. First position the lever bar in place, then slide the ends back on. The retaining tabs should click and the ends will be locked into place again. Putting the springs back into place is easiest with the help of the hook removal tool.
22. Thread the top plastic piece back over the green lever. You may need to press on the green lever just a bit to get the piece back in and again to align the screw holes. 4 black screws to hold this top plastic piece.
23. Put the electrical connector piece back into place. Note that it hooks over the side panel piece. Route the wires into the proper place, so as to not smash them as the two black screws are used to reattach this piece.
24. Put the rubber roller back into place. Steps are the exact reverse of what it took to take it off.
25. Finally, fasten the paper belt drive assembly back down with the 3 bright screws. Note,this piece hooks into the top plastic piece before it is screwed down. Use a small flathead screwdriver, as needed,to make sure the grounding tabs are not messed up as the assembly is put back into place.