When you say check the teflon again, what am i actually checking as each time I have changed it, it doesn't really look that damaged maybe a bit blackened around the entry and exit points but as soon as i change it works fine.
The reason i ask, is every time i have had to change it, it has been pretty stuck and i have ended up having to be quite aggressive to get it out.
I will try loosening the pulleys
The Teflon coupler from 3D Solex is not glass filled and will be more prone to deforming, Its recommended to use this with the I2K washer. Might be good to check it again.
If the belt is loose on the top you can loosen the pulleys on that side so the can rotate and let the tensioner even out the tension. Then re-tighten them again.
Have you tried different rolls? are you using a low roll?
Could be a lot of causes, any pictures of the problem?
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