Epson XP-445 Printhead Replacement: FA04040, FA04060, and Black Ink Failure Troubleshooting

Question

I watched your video, "Extreme Bone-Dry Printhead Cleaning: Recovering Epson Printheads Everyone Gave Up On." My Epson XP-445 is no longer printing black. Is it possible to buy a brand-new replacement printhead for this printer? If so, what printhead model should I look for, and do you have any advice regarding the brand, quality, or compatibility of replacement heads?

Answer

Yes, Replacement Printheads Are Available for the Epson XP-445

The Epson XP-445 uses a printhead from Epson's FA040xx family. More specifically, the XP-442/XP-445 parts documentation lists the printhead at reference position 700 as FA04040, with FA04060 shown as its replacement or superseding part number.

This means that when searching for an XP-445 printhead, you will commonly encounter part numbers such as:

• FA04040

• FA04060

• FA04000

• FA04010

• FA04061

Current replacement-part listings also group the XP-445 with FA04010/FA04061 and related FA040xx heads.

However, I would not purchase a printhead based only on the words "FA040xx compatible." Epson has used several revisions of this general printhead design across many Expression, WorkForce, L-Series, and EcoTank printers. Even within the FA040 family, there can be differences in the assembly, ink inlet configuration, cable arrangement, or revision. BCH's own FA040xx documentation also notes that different FA040xx variants exist and should be physically verified rather than assumed to be universally interchangeable.

For your XP-445, FA04040 or its documented replacement FA04060 would therefore be the safest starting point when identifying the correct part.

What Quality or Brand Should You Look For?

If possible, I would look for a genuine Epson/OEM printhead rather than the least expensive unbranded replacement.

Be careful with marketplace descriptions such as:

• "Original"

• "OEM quality"

• "Compatible OEM"

• "Refurbished original"

• "Pulled original"

• "New original"

These phrases do not necessarily mean the same thing.

A truly new OEM Epson head would be preferable, but because the XP-445 is an older printer, the marketplace can contain new old stock, refurbished heads, heads removed from other printers, and aftermarket units advertised alongside genuine parts.

Before purchasing, I recommend comparing the seller's photographs with your original printhead. Check the part number, ribbon-cable connections, mounting points, ink inlet arrangement, and overall shape rather than trusting printer compatibility lists alone.

You can contact an Epson parts distributor in your country, check printer-parts suppliers, or search marketplaces such as eBay. If buying from a marketplace seller, I would strongly favor a seller who clearly identifies the exact part number and condition and has a reasonable return policy in case the head is electrically or mechanically incompatible.

Before Buying a Printhead, Make Sure the Printhead Is Actually the Problem

Because you mentioned that only black has stopped printing, I would not automatically conclude that the entire printhead needs replacement.

There are several possible causes of a missing black channel:

1. A severely clogged black nozzle channel

If the black channel has dried completely, normal cleaning cycles may no longer restore it. This is the type of situation discussed in our extreme printhead-cleaning video.

2. Ink is not reaching the printhead

A cartridge can contain ink while still failing to supply it correctly. A blocked vent, poor cartridge outlet seal, air entering the ink path, or another supply problem can result in a completely blank black section on the nozzle check.

If you are using compatible or refillable cartridges, this is particularly worth checking before replacing the head.

3. The capping station or pump is not drawing ink properly

The maintenance station underneath the printhead performs an important part of the cleaning process. When the printhead parks on the cap, the pump should be able to create suction through the head.

If the cap is dirty, incorrectly sealing, blocked, or the pump is failing, repeated software cleaning cycles may accomplish very little. In that situation, replacing the printhead would not necessarily solve the underlying problem.

4. The black channel inside the printhead may have failed

If ink can reach the head correctly and the black channel remains completely absent despite proper cleaning, the black channel itself may be physically clogged beyond recovery or electrically damaged.

Piezoelectric Epson printheads are permanent-style printheads rather than disposable thermal heads integrated into each cartridge. A failure of one channel can therefore occur while the other colors continue printing normally.

5. There may be an electrical issue rather than an ink-flow issue

The printhead communicates with the mainboard through flat-flex cables. Contamination, corrosion, damaged contacts, or an electrical failure affecting one firing channel can produce symptoms that resemble a clogged printhead.

If the black channel disappeared suddenly rather than gradually becoming weaker or developing missing nozzles, I would keep an electrical problem in mind.

Use the Nozzle Check Pattern as Your First Diagnostic Clue

The nozzle check can tell you quite a bit.

If black became progressively worse-first showing gaps and then eventually disappearing-that behavior is more consistent with ink starvation or clogging.

If black went from printing normally to being completely absent immediately, particularly after printhead cleaning, disassembly, liquid exposure, or reconnecting cables, an electrical problem becomes more suspicious.

If the black section occasionally returns after cleaning but disappears again, I would investigate the cartridge, ink delivery, capping station, and pump before condemning the printhead.

Also avoid running a large number of automatic cleaning cycles consecutively. Besides consuming considerable ink, repeated cleaning will not repair a failed electrical channel and may not overcome a severe obstruction.

Be Very Careful When Replacing the XP-445 Printhead

If you do decide to replace the printhead yourself, disconnect the printer completely from power before touching the printhead or its ribbon cables.

One of the most serious mistakes during Epson printhead replacement is getting cleaning fluid or ink onto the FFC cable contacts and reconnecting them while they are still wet or contaminated. A short circuit can damage not only the replacement printhead but also the mainboard's printhead driver circuitry.

Inspect the ribbon cables carefully before installing the new head. They should be:

• Clean

• Completely dry

• Free of corrosion

• Free of burned contacts

• Fully inserted into their co