Introduction

This guide will show how to remove the chassis from a Professional Series PS77401 toaster. The chassis may be damaged from a high height drop and may need replacing to allow even toasting. This guide is not a repair guide and requires a replacement toaster chassis.

Image 1/1:
  • Make sure that the toaster is unplugged before attempting any sort of disassembly!

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Image 1/2: If this is the first time detaching this piece, it will take some effort to remove. Be careful as pulling too hard can cause damage to the inner lever mechanism. Image 2/2: If this is the first time detaching this piece, it will take some effort to remove. Be careful as pulling too hard can cause damage to the inner lever mechanism.
  • Grip the black plastic lever nub firmly and carefully remove it from the metal lever. Use one hand to hold the toaster in place while you pull the lever nub with the other.

  • If this is the first time detaching this piece, it will take some effort to remove. Be careful as pulling too hard can cause damage to the inner lever mechanism.

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Image 1/3: Flip the toaster back over and slide off the shell making sure to slip the toaster lever (now without the black plastic nub) through the lever opening in the shell. Image 2/3: The outer shell should now only be connected by its internal wiring. Image 3/3: The outer shell should now only be connected by its internal wiring.
  • Flipping the toaster upside down, use a T7 Torx Screwdriver to remove the four 10mm screws that keep the outer shell attached.

  • Flip the toaster back over and slide off the shell making sure to slip the toaster lever (now without the black plastic nub) through the lever opening in the shell.

  • The outer shell should now only be connected by its internal wiring.

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Image 1/2: The shell should now be completely separated from the rest of the toaster. Image 2/2: The shell should now be completely separated from the rest of the toaster.
  • Locate and remove the two 8mm screws that attach the circuit board (located inside of the shell) from the shell itself using the Phillips #2 screwdriver.

  • The shell should now be completely separated from the rest of the toaster.

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Image 1/3: To remove the circuit board, pull apart the two side tabs while releasing the middle tab simultaneously. Image 2/3: Pull the circuit board out of the slot. Image 3/3: Pull the circuit board out of the slot.
  • Locate the small circuit board attached to the base of the toaster.

  • To remove the circuit board, pull apart the two side tabs while releasing the middle tab simultaneously.

  • Pull the circuit board out of the slot.

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Image 1/3: Flip the toaster around and proceed to remove the two remaining 8mm screws. Image 2/3: The toaster chassis should now only be connected to the base via wiring. Image 3/3: The toaster chassis should now only be connected to the base via wiring.
  • Using a Phillips #2 screwdriver, remove the front two 8mm screws attaching the chassis to the base.

  • Flip the toaster around and proceed to remove the two remaining 8mm screws.

  • The toaster chassis should now only be connected to the base via wiring.

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Image 1/1: Remove these screws to release the power cable.
  • There are two phillips 8mm head screws holding the power cable to the base.

  • Remove these screws to release the power cable.

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Image 1/2: Disconnecting the cables in the middle is recommended to be able to reconnect new wires from a new chassis easily. Image 2/2: Disconnecting the cables in the middle is recommended to be able to reconnect new wires from a new chassis easily.
  • The following wires must be disconnected to be able to remove the chassis: Blue x2, White x2, Bronze x1

  • Disconnecting the cables in the middle is recommended to be able to reconnect new wires from a new chassis easily.

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Conclusion

To reassemble your device, follow these instructions in reverse order.

Kevin

Member since: 01/23/2014

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Cal Poly, Team 10-36, Maness Winter 2014 Member of Cal Poly, Team 10-36, Maness Winter 2014

CPSU-MANESS-W14S10G36

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