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Canon Imageclass D1120 'Output tray full' Error

Canon Imageclass D1120 'Output tray full' Error

(OP)
I am getting a 'Output tray full' error on this printer model, when in fact the output tray is not full.

Having dismanteled the printer to fully access the exit tray paper bail. I find its a split bail with the right most part of the bail activating the sensor. it appears that this gets stuck in the raised position even though the other half of the bail is in the lowered position. Thus the chopper circuit is interupted causing the fault.

There is no obvious reason for the bail to get stuck other than a design fault. I have used slicon grease to relubricate the clip points on the left and right hand sections of the bail but TNA.

Also I have tried to add weight to the right most bail plate and sensor arm using thin metal 'Battle damage' repair tape. this has eased the problem somewhat, but it still gets stuck occasionally.

Has anyone else had this problem and how was it resolved? Is there a newer (redesigned) version of the paper bail available?  

'If at first you don't succeed, then your hammer is below specifications'

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