If it’s related to the gears, then it should happen somewhat regularly. If it’s not cyclical, then it could be hobbed bolt related or in the bearings- how loose is the hobbed bolt? Rotate the gears with the power off, empty of filament and disconnected from the extruder wiring harness and see if you can further locate the source.
You can, if you’re under warranty still send the toolhead back for evaluation if you prefer. To start a return, send an email to support@lulzbot.com with the following information:
Orias, thanks, I will try those tips. Don’t really want to be without the printer right now, do you have loners for customers to use while their’s are being fixed?
We don’t typically offer loaners, but we do have another option. You can use the Rush Replacement option, where you purchase a replacement toolhead. Once it arrives, you’d be free to send back the original for evaluation/replacement or a refund on the item cost of the replacement toolhead.
I just did that too, I started with a slightly smaller bit and turned it by hand. The plastic comes out as a curl. Then I went to a larger bit, still smaller than 3 mm. Then sensing with the filament I found the clog was gone.