Hi John - I had the same problem, whether I was using genuine HP supplies (paper) or 75gm/m copy paper from Staples. Fixed it by going into the Printer Web Settings and changing the default media type from “Any” to “Plain”. This way, the printer knew to apply the right pressure when picking up the sheet from the duplexer, thus avoiding a jam. Hope this helps.
When reinstalling the drive, I trimmed the top and bottom rubber pieces for a better fit.
I had issues reconfiguring Time Machine to access the newly formatted disk. Time machine returned a “Please enter Server Password” - solved by going into Airport Utility and changing the Base Station Password.
I recommend also marking the top of the small connectors with an ink dot - at least the small three-wire one. Turn it over accidentally like I did and wonder why it won’t seat.