PattyChuck

Well, that fixed everything! I have absolutely no idea how the GCode Flavor got changed. That's going to bug me for awhile. Thanks to everyone for their help!!

Well, that isn't Cura code, but your issue is the E steps. Basically, the way this model sliced, you are trying to extrude WAY too much filament. A normal value would be like E0.57321, but this code is like E3.26400. I'm not sure why this is. Was this code generated using S3D? Also, what version of Cura are you using? This is not a mechanical problem with the printer, but instead an issue with your slicer. It's no wonder the feeder is kicking back. This code was generated with Cura 15.04.2. Here's a copy of the profile exported from Cura.

Based on my limited research, it seems as though the default current is 1250mA, but that changing the current really doesn't make much of a difference anyway. Thoughts?

Have you touched the feeder tension at all? If you can supply the gcode for a model that is giving you problems, I can also try printing it to see if I can recreate the issue. What @neotko said about the extruder motor power command in the gcode from S3D is also viable, but I don't have a license for S3D so I can't confirm. D'oh! I forgot to add that to my list of things I've tried. I went from all the way loose to all the way tight, and the problem either still persisted or it got worse. Here's a link to a 20mm cube that prints successfully, but it clicks like crazy. Parameters are as follows: Layer Height - .1mm Print Speed - 35mm/s (30mm/s bottom layer) Temp (Extruder/Bed) - 215/70 Flow - 100%

Build plate is totally level. The clicking happens during all stages of printing, whether it is the first layer, or the last.

Do you know where that is in the new S3D? I can't find it...

Okay, it must be something weird going on in Cura, because I tried slicing a 20mm cube in Simplify3D, and it worked like a charm (didn't click once during the entire print). I am using Cura 15.04.2.

I have a new UM2 Extended, and for the first several prints, was absolutely flawless. I went thru about 3KG of filament before I started seeing this issue, and it seemed to have just all of a sudden happened. My extruder, as seems to be a common occurrence, clicks. And clicks. And clicks. 80% of the time, the print will execute without failure, but 20% of the time, the extruder skips so much that eventually it will grind the filament to where it won't go thru the Bowden tube any more. Here are the steps I have taken to try and fix the issue: Started by doing the "atomic method" of cleaning the nozzle. Still clicks. I printed and installed the Alternate Extruder by IRobertI. Still clicks. My printer came with spare parts to build a second extruder, so I completely replaced everything on the hot end. Still clicks. I reinstalled the factory extruder. Still clicks. I have tried all the "default" settings in Cura. Still clicks I tried printing in a range from 210° - 220°, and varying feed rate from turtle to rabbit. Still clicks. I'm using ColorFabb filament, tried two different spools, although both spools measure in the range of 2.84-2.87mm. Still clicks. The only thing that seems to stop the clicking is if I manually adjust the Material Flow while the printer is running. To completely eliminate the clicking, I have to dial the flow down to somewhere in the 35-45% range (seems to be print-dependant). However, most (but not all) of the time this results in a failed print. I'm at a loss as to what to try next. I work in the same room as my printer, and the clicking is like someone smacking a ball-pean hammer on my head, since I know the printer has printed fine before and it shouldn't be clicking. Any help would be greatly appreciated.