Wow, I had this EXACT problem recently. I thought it was something to do with the belt so I started to replace it. When I removed the carriage, I realized the belt wasn't even attached to it! The carriage was broken where the two posts that hold the belt to the carriage were. How it worked at all... I don't know. I think this is a result of the end user trying to force the carriage to move, either during a jam or some other time.
When I showed it to HP, they said yup! They'd seen that before.
So maybe this is your problem.
Kiran
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