Wish I knew what I did...
Well, I still have the 1st and 2nd gen models - the ones with the blade type grinder. Neither of these really has ever failed, and I might just go back to the 1st gen at some point (if I can get a new carafe - the old one has a sprung lid - or I might just safety wire it back into place).
In any case, I spent a couple of hours this early evening opening up the current model. Torx 10, in case anyone is so inclined... lol... plus there are smooth plastic inserts that cleverly hide many key screws in the top.
Took a look inside the bottom of the unit. There appears to be a sealed plastic box in there, with wires coming in and out. Didn't try to get into that. Satisfied that I could find nothing amiss in that area, I sealed it up and pulled the top (courtesy of the many aforementioned hidden screws). Got a general idea of the main components, but frankly I also didn't see anything grossly amiss in there, either. I focused on the trap door, not big surprises there (other than the somewhat circuitous connection between the manual lever and the door itself). I then looked at the safety relays for the filter basket - these seemed to be in order, however, the safety relay for the hopper has a rather long row to hoe, with two stacked plastic rods finally activiting the sensor. With the hopper off I tested the grind a bit, and could see that the trap door was opening and shutting in the right sequence now. Hmmm. Tightened up all the screws I could get to in the inner top area. One was very loose, but that might have been my doing as I was trying to see if I could pull the grinder (not successful, due mainly to the white goop the mfg put on all the screws it didn't want fooled with). But who knows? I also shook the thing thoroughly upside down while it was open. Unground beans were coming out of somewhere, don't know exactly where, wasn't from me, I know that much.
Since the testing seemed to be satisfactory now, buttoned it all up, brought it back to the kitchen, and it just got through grinding and brewing a 4 cup pot with no glitches. Knock on plastic. And this thing is about 95% plastic, save for the thin stainless shell (a metal veneer if you will, over plastic), the copper wiring, and the aluminum heating assembly.
I held off putting the smooth plastic screw covers back on - they were a chore to get off (I used a fine dental pick) so if I need to go back inside I won't have to deal with them next time. They serve no real function other than to hide the screw heads and maybe keep some coffee dust out of them.
Time will tell. This thing made me late for work yesterday ... not gonna let it do that again... lol...
It's *possible* that in the course of the recommended cleaning of the ground coffee path, that something got out of alignment in the trap door area. Not sure how that would affect its timing, but who knows? I guess I'll find out soon enough...