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Brother laser printer stops working with Replace Toner message, even with toner left in the TN-450 cartridge, and how to fix it by turning back the reset lever gear on the cartridge. When you insert a brand new toner cartridge, the printer turns the cartridge reset lever to the Not New position, and resets its internal toner meter to Full. Everything works OK as long as you don't disturb the installed cartridge.
However, if you swap new and partially used cartridges, the internal toner meter becomes unsynchronized with the actual amount of toner left in the cartridge. To fix this problem, you can turn back the "reset lever" of the toner cartridge. This makes printer think that the cartridge is new. The video shows you how to do it. You need a Phillips type screwdriver to gain access to the reset lever.
Follow the directions carefully to avoid spilling the other gears when you remove the black plastic gear cover. With the cover off, the gears are loose and will fall off if you tip over the cartridge or pull off the cover carelessly. You can put back the loose gears in the proper order and orientation using another cartridge as a model. (Don't spill both!)
Remember to order a new toner cartridge promptly because your old one will run out without warning.
To reset the Replace Toner message using key presses on the printer, see • Fix "Replace Toner" on...
Note that this video applies to the Brother TN-450 toner cartridge and the similar TN-420 cartridge. The Brother TN-350 cartridge uses a different mechanism. The TN-350 has a clear window that allows the printer to peek inside the toner reservoir. When the toner gets low, the printer can see all the way through, and it issues the Replace Toner message. To continue using the TN-350 cartridge, cover the clear window with a piece of black tape.