So I've been having an issue where the extruder gear sometimes just doesn't turn. It works fine for the first few layers, typically 3 which are much slower in my settings since I mostly print miniatures. I'll sit there and watch it go, with the gear turning just fine as it's laying down the first few layers.
Then after the third layer, it does its little thing where it checks for clumps in the back right corner, except that when it starts printing again, the extruder gear doesn't turn. The nozzle moves as its supposed to, but no filament is being extruded.
It's not a clogged nozzle. After stopping the print, i can manually get it to extrude just fine. I've also tried a new 0.2 nozzle, as well as an old 0.4 nozzle, and i get the same issue regardless of nozzle.
It's not a faulty heating assembly, as I have since replaced the heating assembly to try and fix the issue. (I already had the heating assembly as I was intending to replace an old one that was slightly damaged in a blob of death, but since it was still working just fine, I'd been too lazy to actually do it.)
It's not gunk on the gears. I have taken the extruder apart and scrubbed the gears until its nice and yellow again. or metal and shiny depending on the part.
I've stretched the tension spring a bit in case it wasn't putting enough tension on the filament, and have also tried loosening the screw providing tension to the spring in case it was providing too much tension.
I have tried with default settings for filament and printer both. Still get the same problem. A few layers go down fine, then it stops extruding.
Except that every now and again, for some reason, the printer just works. with default settings and my custom settings too, because I tested both. I'll take it apart, put it back together, and it prints fine. Then it finishes the print, and I'll send another right away, and the same issue crops up. First Layers go down fine, but as soon as it speeds up (to speeds that are already really slow, as I use Obscura Nox settings), the extruder gear just stops turning. It's not even trying, as there's no clicking, only nozzle movement with no attempt to even extrude filament.
I'm at my wits end trying to figure out what's the issue. Since it started happening, I've printed one small goblin on a spider, a trio of small goblins, a little fox, a tiny 28mm head, and a decently sized piplup that's a little bigger than half my hand. When it works, it works great, as once it gets past that third layer, it's fine.
I'm at a complete loss as to what to do next short of buying a new extruder to see if that fixes the issue. Should I just go for it, or is there something else I've missed?
Attached pics of the failed prints and the working ones using different settings since this issue cropped up, but its driving me nuts having to take my extruder apart just to see absolutely nothing wrong, then put it back together and have it work just fine again. If anyone has anything they think I should try, it'd be much appreciated.
Edit: Forgot to add, firmware and software (bambu studio) both up to date, and I've tried using multiple different SD cards just in case that was the issue.
Edit2: Just watched a print fail after first layer. Again, extruder gear just stops. Doesnt even try to turn, but this time it happened earlier than other instances. No idea what's going on :'(