Clicking Sound From MK4S Extruder Gear – Found Broken Main-Plate on Heatsink  

Clicking Sound From MK4S Extruder Gear – Found Broken Main-Plate on Heatsink

Hi everyone,

I wanted to share an issue I had with my Prusa MK4S in case it helps someone else troubleshoot a similar problem.

I started hearing a repeated clicking sound coming from the extruder gear during printing. At first, I thought it was related to a clog, so I started troubleshooting with a cold pull procedure. The cold pull improved things slightly, but the clicking sound continued.

After opening the extruder assembly, I discovered that the printed part called the “main-plate on the heatsink” was broken.

The broken part was causing poor alignment inside the extruder, which eventually led to nozzle clogging and the clicking noise from the gear.

Luckily, I still have my old Prusa MK3, so I used it to print a replacement part. After replacing the broken main-plate, I repeated the cold pull process again, and this time the problem was completely solved. The printer is now working normally with no more clicking sounds.

Hopefully this helps anyone experiencing unexplained clicking noises from the MK4S extruder. It may not always be just a simple clog or tension issue — it could also be a damaged printed structural part inside the extruder assembly.