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I think that your developer side seals are causing the problem. In my lovely "drawing" is what I had to do to the dv side seals to fix the same type of problem, where it was dumping on the sides of the unit.
Here is the drawing, plus the SMC printout from my machine.
Thanks mate. I'll try out the "new and improved" side seals. Hope this will end my long months of torture.
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