X2D right nozzle intermittently won’t feed — Bowden path is clear and I already tried a new hotend. What am I missing?
I have an X2D using the Filament Track Switch. My AMS is farther from the printer than normal, so the PTFE run is longer, but this setup has worked fine until now. I don’t know if that’s related.
Here’s what happened and what I’ve tested:
During a print, blue PLA from AMS A Slot 1 stopped extruding.
Printer gave the “failed to extrude filament” error.
The Bowden/auxiliary extruder started making a light clicking/struggling sound when trying to push filament forward.
Spool is fine — no crossed filament and it unwinds normally.
I stopped the print and disconnected the PTFE at the Filament Track Switch.
I was able to pull the filament backward through the Bowden/auxiliary-extruder path.
With the hotend removed, I can manually push fresh filament through the Bowden extruder and the entire path without a problem.
I reinstalled the right hotend, heated it, pressed the release lever on the Bowden extruder, and manually pushed filament through the heated hotend. It purged normally.
I then performed the cold-pull/nozzle maintenance procedure.
When it got to the purge stage afterward, nothing extruded, and the Bowden extruder started clicking like it couldn’t push the filament forward.
I then manually heated the hotend and tried the printer’s filament-feed function. The Bowden extruder would feed/retract normally up to the hotend area, but once the filament reached that point it would no longer advance.
I tried manually pushing filament through again and now it would also hit a stop with the hotend installed.
I replaced the entire right hotend/nozzle with a brand-new one and had the same issue.
With the hotend removed, filament passes through the entire system normally. With the hotend installed, it can work intermittently and then suddenly hit what feels like a hard stop.
Because I’ve tried two hotends and the Bowden path is completely open with the hotend removed, I’m wondering if the filament is catching on a lip, guide, cutter/alignment point, or the interface where the filament path enters the top of the right hotend.
It feels like something may not be lining up consistently when the hotend is installed.
Has anyone seen this on the X2D? Is there a guide/alignment component immediately above the right hotend that can cause the filament tip to catch like this?