Howdie. Is that 500,000 or 5 million? Big difference. Anyway...
1. The charge roller (or the mag roller located in the developer unit) I believe is behind the the bypass door on the upper right hand side of the copier (below the document catch tray and above the large capacity paper deck if you have one). It's quite possible your spacing got off or the top side damaged on the roller. The unit should come out after removing several screws...sorry I don't have the manual or a photo to aid you. Remove the screws and GENTLY pull out the black box-like object which is the developer unit and the toner hopper sits on top I believe.
I think the developer units should last about 2-3 million pages but maybe your died if you're at 500,000 pages.
I'd recommend getting a new developer unit instead of messing with just the roller...I tried to be cheap and messed up one once and got toner everywhere. Just guessing but they're probably like $900 or so.
2. If you're machine is at 5M pages, you're probably due for a new drum and drum blade (doctor blade). If you're at 500k then I believe you just clean and flip the drum blade and use it for another 500k prints. I recommend flipping or getting a new drum blade; they don't cost that much anyway.
3. I don't think it is your laser but while you're changing your drum blade you might as well look at it and make sure none of those toner clumps got on it or flew around. I think there's a drum sensor on that model too. Just make sure it's clean while you're taking everything apart.
Hope this helps you. Oh and clean or change the coronas if you haven't and there's little pads that get replaced if you're not buying a whole new unit.
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