I have a DVL-91 and I have had to do a little work to it(realign the DVD laser gear) and in doing so, now the tray when slid in, stops with about 2 inches sticking out, or as I slide it in the entire laser assembly moves up and stops the tray from going the rest of the way in. I can provide photos. I believe it has to do with the gear that moves the laser assembly up and down, but I cant quite figure out how its supposed to be oriented.

You need to remove the tray from the unit. Power the unit on and make sure the unit has finished the open cycle. Then put the tray back in.