Creality Ender 3 Max Neo
PLA, temp 200 - 225
Slicers: Cura and Prusa
Gcode: Old and newly created
SD card: Old and new
Physical build: Stock w/ OEM replacement parts
Very short version: After several removed clogs, replaced PTFE tube, several nozzles, replaced extruder feed gear, I'm still getting clogs. Last night, when I pulled the PTFE tube (filliment was too difficult to pull from extruder), a curly (the kind you see from a clogged nozzle) length of soft filliment came out of the top end of the heat break.
Now there is so much residue at the top, I can't get the PTFE tube back in. There doesn't seem to be a way to clear the residue. With everything else I've done, I'm about ready to replace the entire print assembly.
I'm wondering if wet filament might cause this. Any way to recover before I do a replacement of the print head assembly?
Far more detail:
A few weeks ago, I got a thermal runaway error. I fixed that, but I was not able to get any successful prints after. Prints looked like the nozzle was too close to the bed. Did a level with no help. Checked the nozzle and removed a clog. Tried the print again with no success.
Leveled again, cleared clog and noticed the PTFE tube was cooked. Replaced the tube. Tried a different roll of filament. No dice. Re-configured esteps (subtle change), cleared clog, still failed. Noticed the extruder gear moving, but filiment was not. Gear looked worn. Replaced it, clog again. When I pulled the PTFE tube, the end was jammed up with an inch or so of filament hanging out the end. Some of the warm filiment must have broken off and cooled because I can't get the tube back in.
Almost every test print started ok. I'd get a purge line (some better than others). The print would start the outline, but the quality looked like a thin brim. Sometimes I tried adjusting Z during the outline or waiting until the main print. Neither helped. I'd get a crappy first layer (nozzle appeared to be too close) or no first layer at all.
Could wet filament be the cause of my issues?
Can I recover the heat break, and how? If not, I'll replace the entire print head