Tips look fantastic but diameter is too big for reentry  

Tips look fantastic but diameter is too big for reentry

I've been messing with this MMU since it was one of the first MMU2s.  It seems the longer I use it, the worse it gets.  I know the problem I have is exactly this:

When a filament is pulled, the tips are wider than the filament.  Here's an extreme example. Filament diameter is 1.80mm, the tip is 2.60mm.  Typically, the tip diameter is around 1.95mm or so.  I've read as many of these forum posts on extruder tuning, tried everything.  I sometimes get slightly narrower tips when I put a new bowden tube in the extruder.  The wider tips will pass through the extruder gears, but won't fit into the heat chamber.  The gears start chewing the filament, and that's the end of hands off printing.  It's now happening on every single 'removed' filament tip.  My current solution is to arrange the filaments so that the selector is far enough away from the just removed filament that I can push it out, clip the end off, tuck it back in while the next filament is in use.  In other words, I have to have my eye on the printer 100% of the print time.

I'm to the point where I'd just like to put a vacuum or drain in the MMU tray to prevent overflows and just cut the wide tips off by default, but I see all these posts with success stories.  The slim chance of proper operation keeps me trying to find the real problem and eliminate it.

Has anyone else had this problem?  The solution is NOT to reduce the spring tension in the Extruder Gears, because the wider tip passes through the gears just fine.  It is too wide to get back into the heat chamber, which is odd, because it was  able to come out from that chamber effortlessly.