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Extruder Gear Misalignment  

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Orion Strayer
(@orion-strayer)
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Extruder Gear Misalignment

I've been having problems loading and extruding filament on a Prusa XL Multi-Tool due to what appears to be misalignment of the extruder gear. When loading, the filament seems to get squeezed between the gear and the idler door. Then the filament tip usually gets caught on the rim of the hotend tube, producing the notch that you can see in the photo. Even if I manually feed the filament into the hotend tube (which is more challenging than it should be, since the filament needs to bend to get past the extruder gear), the pressure of the filament on the idler door makes the extruder gear skip.

Here is a sketch of what I think is happening:

The extruder gear is further forward than it should be, forcing the filament to curve and pressing it against the idler door.

What I don't know is how this could have happened or how to fix it. I already tried completely disassembling the extruder gear assembly, cleaning the gears, and putting it back together.

(As a side note, this is part of a shared small printing lab for a master's program.)

Este debate ha sido modificado el hace 2 days por Orion Strayer
Respondido : 20/05/2026 5:16 pm
Orion Strayer
(@orion-strayer)
Miembro
Topic starter answered:
RE: Extruder Gear Misalignment

Here's another photo of what's happening, but from the side.

Respondido : 20/05/2026 5:30 pm
Diem
 Diem
(@diem)
Illustrious Member

I wonder - have the two idler pressure screws drifted out of alignment with each other during adjustment/maintenance?

Cheerio,

Respondido : 20/05/2026 10:52 pm
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