How to Refill Epson T040 and T041 Cartridges for the Epson C62 When the Needle Hits a Hard Block Inside

Question:
I am trying to refill Epson T040 and T041 ink cartridges used in the Epson C62 printer. When I attempt to insert a refill needle through the ink outlet, the needle hits a hard barrier inside the cartridge and cannot go further. How can I properly refill these cartridges?

Answer:

Why the Needle Hits a Hard Barrier

The Epson T040 (black) and T041 (color) cartridges used in the Epson C62 are designed with internal plastic chambers and sponge structures. When attempting to refill through the ink outlet (the bottom port), the needle often runs into a solid internal plastic wall.

This design is intentional. Epson created the cartridge structure to prevent easy refilling and to control ink flow. As a result, inserting a needle through the outlet rarely works and can even damage the internal valve.

Correct Method: Drill a Refill Hole

The proper way to refill these cartridges is to drill a refill hole on the top of the cartridge, rather than trying to inject ink through the outlet.

You will need to drill through two layers of plastic on the cartridge top.

Steps to Refill the Cartridge

1. Remove the cartridge from the printer.

2. Locate the top surface of the cartridge.
   You will usually see a label covering the plastic casing.

3. Drill a small hole on the top of the cartridge.
   Use a small drill bit (about 2-3 mm).
   You will feel two layers of plastic as you drill:

   • The outer cartridge shell

   • The internal chamber cover

4. Stop once both layers are penetrated.
   Do not drill too deep, or you may damage the sponge structure.

5. Inject ink slowly using a syringe.
   Insert the needle through the hole and refill gradually so the sponge can absorb the ink evenly.

6. Seal the hole after refilling.
   You can seal the hole using:

   • A rubber plug

   • Hot glue

   • Waterproof tape

Sealing the hole is important to prevent air leakage and maintain proper ink pressure inside the cartridge.

Important Tips When Refilling

Refilling older Epson cartridges like the T040 and T041 requires patience because they use sponge-based ink storage.

Keep these points in mind:

• Refill slowly to avoid air pockets.

• Do not overfill, as excess ink can leak into the printer.

• Allow the cartridge to sit for a few minutes so the sponge absorbs the ink evenly.

• If printing quality is poor after refilling, run 1-2 cleaning cycles from the printer utility.

Also note that some cartridges may include chips or internal restrictions that limit reuse. However, many early C62 cartridges are relatively refill-friendly once a refill hole is created.

Addressing printer issues can often become complicated because many of the problems involve hands-on inspection and mechanical work. For that reason, we're not able to provide remote troubleshooting or repair support. However, we do offer an in-person evaluation and repair service through our local diagnostic facility: BCH Technologies Printer Repair Service (https://bchtechnologies.com/printer-repair-service).

Due to high demand, our repair services operate on a first-come, first-served basis, and it may take several weeks before we are able to accept a printer for drop-off. Our repair structure allows us to work on either complete printers or specific components, with detailed instructions provided for each process. That said, we recognize that our repair rates may not be the most economical option for everyone. Because of this, we strongly encourage customers to explore self-help options through online research.

A good place to begin is YouTube, or directly through the BCH Technologies YouTube channel homepage (https://youtube.com/@bchtechnologies). Use the search icon next to "About" on the right side of the menu bar to look for videos related to your specific printer issue. I receive dozens of messages every day asking whether we have a video on certain topics. After producing videos for more than nine years, it's difficult to remember every single one. Using YouTube's search feature is usually the fastest way to find the information you need. YouTube may also recommend helpful videos from other channels that could assist with your repair.

Thank you again for reaching out and for supporting BCH Technologies. We truly appreciate your interest and hope this information helps you successfully refill your Epson C62 cartridges.