[Mikkel Breiler]

Eeyore wrote:

...
Trying to find out what was causing the problem I very gently 'poked' a bit more
and now I've jammed it even worse !
Is *anyone* at all familiar with how this crazy drawer mechanism works ?

Most mechanisms of this kind rely on a small dc motor, the axle of which turn a drive
belt to a pulley which is then scaled down for torque and slow speed. At this point
the tray is connected, it is then that some clever electronics must detect by
contacts that the tray is in closed position or in open position at which points
motor power must be cut. It is usually possible to push the tray and the strain
disconnects the contact that means tray open, thereby prompting the electronics to
power the motor for moving the tray in, unt ilit is again stopped and a contact
meaning closed is activated.
Usually but unfortunately not always the tray has a front plastic part which is
detachable. This part is wide enough to cover the tray and part of the opening on the
front plate whre the tray comes out.
In order to remove it you must determine which way it detaches, on most systems it is
done by moving the plastic part up in relation to the tray, but most often you must
pull the tray out a little to clear the front plate.
Many systems emply some sort of a grip on the tray while in closed mode, which means
you cannot easily pull the tray out using your fingernails. And doing so *might*
damage the tray and or the closed tray detection contact.

The trayscan be implemented in a lots of different ways with the detection contacts
on the point where the tray must stop or on any cogwheel in the assembly.
Sonys trays of the late 80s and early 90s designs for instance, are notorious for
getting out of sync because the movement on the tray is calculated not by the trays
position, but its relation to the cogs on the tray on the cogwheel which travels a
certain milage. When the vogs are worn the tray easily slips, and chaning one habit
of pushing the tray tyo make it close shows up years later as not only a bad habit
but a destructive behaviour. There is a reason why they label the buttons Eject or
Open/Close. Quite possibly the manufacturers one by one realise that people are prone
to push the tray - and actually do so regardless on what the ejection button is
labelled.

I think it is best to attack the problem from the other side, in the absence of a
service manual, or a hole for inserting a straightened paperclip.
It is probably very difficult to remove the cassette while the tray is closed, but
perhaps locating the motor and turning the axle by fingers will determine wether the
mechanism is slipping due to a drive belt getting too old or wether the lubricants
have gone solid, sticky or even turned to a thick paste or powder.
using your fingers on the inside of the deck is should be possible to wind the motor
axle by hand and also help the tray out. Once out remove the cassette and set about
gently dissameble the deck and remove the libricants and clean the remains and relube
using grease fro mthe local electronic component pusher.

Not saying this will be easy or possible without some degree of damage, but trying to
move the tray from inside before trying to violate the tray to open from the outside
usually means less damage.

-Mikkel