10.15.2022 - extruder wire issue
Extruder stopped outputting filament halfway though a print. Could hear a clicking noise coming from the extruder/hotend area.
diagnosing and repairing
Initially thought it was a clogged/jammed nozzle or a slipping extruder. Removed a section of filament that was kinked near the extruder. Reloaded filament and resumed the print. Noticed the print was fully failed in the morning. There was darkened sections of filament at the nozzle and a kink in the filament near the extruder gears. I cleared out the nozzle and cleaned the heat break filament tube. I attempted to purge a length of filament and noticed the same clicking noise and no filament was coming out. After examining the extruder I noticed one of the extruder wires was hanging loose.
A few minutes with a soldering iron and this printer was back up and running.
Seems to be a compound error of a partially clogged nozzle and damaged extruder wires. Better wire harness strain relief and proper maintenance procedures for hotends will reduce these issues.