5si/8000 odd jam

[SMHtech]

Hey everyone, i have a stubborn 5si here. PIU is new, fuser is new and all other rollers are good too. this printer jams everytime in spot only right as it exits the printer.it peeks out of the face down assy. and then throws a code. i am thinking it might be the DC controller, or the sensor its self. i have yet to see an actual sensor fail. I have already checked to see if the flags are phyisically broke, and they are all moving freely with no issues. Ive scoured the pages of my service manual and cant find a sensor test to performs. do you guys knmow if one exists for this model? please help Thank you
~Randy

[HP:guy]

What code is in the display?

[sbtiti]

How many pages are you printing? Try printing 1 page just from tray 1 (multi purpose tray) if no error then most likely not an output sensor.

[MR Bill]

Dust fuzzies on the sensor? I know, you said you checked them. But did you take off the top cover to do that? PIU could also be faulty? Even tho you said it has been replaced. Fuser flag messed up? Removing a fuser jam can mess up the flag. I would start right at the fuser.

[prntrfxr]

My thought is if you know the fuser is good, check for debris in the paper path or worn 2nd pass roller. The paper might be delayed just enough to only trip the exit sensor. I am suggesting this only because I'm sure you've tried a new cartridge. If you haven't, go there first and then the PIU area.

[SMHtech]

It turns out that the flag sensor shaft had broken in a spot that wasnt visable on the face down assy. when i moved the flag manualy, the fracture point had just enough drag to carry the flag through the sensor, it wasnt until i had moved the part of the flag at the sensor end that i noticed the other end wasnt moving. removed, reinforced and all is well now. thanks for all the sugestions.
~Randy