I may have it working now. Very frustrating, but I removed both print cores to check them, swapped their positions, and re-did the X/Y calibration. Both sides loaded and unloaded properly. I re-started the previous print job that the failures occurred on, and started with about 2 feet of filament left inside the material station after loading, to force early material changes. Material 1 just went through its material change just fine. Material 2 will be changing over fairly soon, so I will update after that.
While I had not touched the PrintCores in months, I did have failure last week where the BreakAway did not bond to the printbed well, and a big chunk of it came loose during the print and caused all kinds of problems (including several large axis shifts during the print, presumably from collisions between the Print Head and the loose BreakAway section). I am now wonder if that jarred the PrintCore enough that was not positioned correctly in the PrintHead, and that a misalignment was the cause of the material sticking in the PrintCore (but not enough to cause loading problems)? I guess we will see.
And I seem to have bad timing (or luck) with Firmware changes. This is the second time I have had "new" issues right after installing new firmware, but the firmware was not really the cause...
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