New XL Kept Dropping E5.
I finally got my semi-assembled 5 tool XL. Assembly went off without a hitch. However tool 5 always sounded different during the pickup process. It passed the alignments with no problem. After printing I had crash problems occasionally with the pickup of tool 5.
I spent 4 hours looking at every possible place that the alignment could vary. It turned out the the cable support holes where it attaches to the extruder were not punched properly and were off about 3mm. This caused the tool changer to not engage consistently with the head due to the cable support plastic being in the way. I reworked the holes with a dremel tool and remounted and realigned both the docking and the offset since I could not guarantee that the original offset alignment was correct.
I was really disappointed with the poor quality of such a simple part that caused so much trouble. However, my XL is now running like a champ. I thought I’d pass this on so hopefully someone else won’t have to waste as much time as I did.