Xl extruder stops - Hardware, firmware and software help

RE: Xl extruder stops

G_Loc — Thu, 30 Apr 2026 14:57:25 +0000

It appears that heat is a factor - at least on my printer. Over the past week I printed over 10 parts in PLA without any issues. Today I switched over to PETG and only made through just one part before this started happening. As before, power cycling the printer fixed the issue.

RE: Xl extruder stops

OTR — Tue, 21 Apr 2026 06:14:46 +0000

It seems to be related to the cable strain relief. Since the last recommended upgrade, where the strain reliefs were screwed onto the covers of the dwarf board (the 3D models are available for download on the Prusa website), I've only had one more problem. Upon inspection, the cable was slightly taut, so I suspect I hadn't pushed enough cable under the strain relief to hold the plug in the socket. I unscrewed the strain relief, pulled the cable through two millimeters further, and reassembled everything. Now the cable presses the plug firmly into the socket, and it's been working ever since (about two month). However, I suspect it's simply a design flaw by Prusa; they should have used self-locking connectors. But since my XL is a bit poorly designed anyway (I'm just saying internal electronics in the hot zone, which doesn't allow temperatures over 40°C inside the cover, no internal memory combined with the occasional USB stick disconnection problem, no single head calibration...), this is only consistent. Maybe it's better with the newer XLs. But, to be honest, if it works it's really great, apart from the 40° limitation. I just had, like others, a lot of trouble to come that far.

RE: Xl extruder stops

1NSH4N3 — Tue, 21 Apr 2026 02:24:01 +0000

Something to take in consideration may be the stepper motor that drives the planetary gear.
had encountered on another xl printer with similar issues, but in that printer case the stepper was very weak at the point i was able to stop it my touching the planetary with with my finger at medium pressure, (the printer is used industrially so they ended up replacing the head completely with the cables, problem is gone.
Im gonna take that assembly from them and do more digging but i really suspect the stepper to be at fault.
I do have a dwarf board on backorder so i can also rule that out when it eventually gets here.

RE: Xl extruder stops

Ray123 — Tue, 21 Apr 2026 01:58:40 +0000

Hello,

As many people have pointed out, when the extruder gear stops, disconnecting and reconnecting the cable on the dwarf board seems to temporarily resolve the issue.

Is there anyone who can speculate on: (1) what causes the gear to stop, and (2) why unplugging and reconnecting the cable restores it?

RE: Xl extruder stops

nrceptor — Mon, 20 Apr 2026 15:12:42 +0000

I had the stopping problem for many months and replaced the connectors/reseated cables, etc. Support eventually sent me 2 new cables with connectors and the issue has not returned. Apparently it was all from damage somewhere in the cable. My guess is that I may have damaged them fiddling around with the connectors before the fix to the firmware causing the problem was released.

RE: Xl extruder stops

G_Loc — Mon, 20 Apr 2026 14:17:02 +0000

I've been struggling with this issue for some time now and it is quite frustrating - especially considering how expensive this printer was. As others have reported, the extruder simply stops spinning after a certain point. The printer doesn't display any errors and it's not a clog as it starts working just fine after I power cycle the printer. Reseating the cables and printing a new cable support offered no improvement.

RE: Xl extruder stops

Cloud1983 — Fri, 20 Feb 2026 14:07:57 +0000

Sorry bro, but you're wrong about that. 
The flickering, as long as it's barely noticeable due to the high frequency, is normal. But if the frequency drops significantly and it becomes very noticeable, then you can be sure that the extruder stop will next. 
That's how it's been for me every time so far. 
Since I got 5 new toolhead cables, both problems have disappeared for me.

RE: Xl extruder stops

OTR — Thu, 19 Feb 2026 17:05:17 +0000

The toolhead lights always flicker. That was never an indicator for a failing toolhead. Firmware is 6.2.5.

RE: Xl extruder stops

1NSH4N3 — Thu, 19 Feb 2026 14:48:41 +0000

I'm going to leave many tips here for people who are still having issues with the extruder stopping.

I had issues with mine in 2024 and recently had to fix another one (from the same year with similar issues).

These are the things that have helped the most and are the usual fixes that I and other people have discovered in this topic and more.

- The issue with pre-release dwarf boards was a problem in the early models and has not been fully proven to be at fault.

- (if your model has screws that keep the connector pushed into the nextruder ignore this part).If your connection to the nextruder is a press fit with no screws, it's important to upgrade the 'dwarf-cover-connector' and 'dwarf-cover-base' to the 2025 revision.

- If it's been a while, be sure your nextruder gearbox is clean and lubed. If you ever open the gearbox, it is always required to perform a gearbox alignment calibration. Make sure the screws are not overtightened, they just need to be snug.

- Be sure that you aren't putting too much pressure on the filament. The top screws from the filament sensor lever should be mostly flashing with the part.

- Inspect the nozzle for any damage to the shaft (dent where the screws hold it in) Compared to nextruders from the smaller models, where they are thumb screws, it is very easy to bend the nozzle shaft. However, due to the variation in filament thickness, it can randomly stop extruding if it's bent and hits a thicker part on the filament.

- Try printing on a different spot on the plate. If it prints fine in the back of the printer and it refuses to print in the front area you may have a warped steel sheet, get a new one.

- Flexible filaments may also be a challenge for an XL printer due to friction caused by the longer PTFE tube. If you ever intend to use flexible filaments, a top shelf spool holder is the best solution. You can feed the filament directly into the nextruder and bypass the tube completely.

I hope that something from here is helpful. My machine doesn't have any problems anymore and I also quickly fixed the second printer. Due to a bent nozzle tube, the filament was unable to extrude in the second case. The gear was causing constant jams due to grinding the filament and pushing plastic parts into the gearbox.

RE: Xl extruder stops

jan.d.slay — Thu, 19 Feb 2026 13:44:36 +0000

Does your toolhead light flicker when printing if it is on? If so, you could clean your contacts at the junction of the cable harness and the extruder. That's supposed to fix it. Do you have 6.2.6 or 6.4.0?