I agree with Nick,
I reamed out the aluminium, and added more chamfer to my E3D, primarily to use slightly oversize nylon strimmer filament, but this stopped any jamming. It is also key not to over retract, you don't want to remove the molten material from the head, just remove the pressure.
Andy
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nick-foley 5
Yeah, it's tough. I struggled with this for as long as I used the E3D. Others haven't had as bad of an experience. I could only use XT or ABS filament without clogging, because it's less sticky when molten. I ended up swapping out the E3D last week because I was tired of hearing that cooling fan and wanted to be able to print in PLA again. Put in the UBIS hotend, no more problems...
Reaming out the aluminum heatsink to be a few tenths of a mm larger in ID might help, as well as making sure the stainless steel tube has a nice clean chamfer where the PLA enters. Cutting down your retraction distance to 1mm mostly solves the problem, but then your print quality may suffer, depending on the part.
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