Been scratching my head over this one for a couple weeks now. My tool changes started failing intermittently, maybe one in twenty at first, but it's creeping up. The toolhead gets to the dock, the motor runs, and every so often the tool just stays attached or half releases. Then it'll work fine for an hour and do it twice in a row.
What's throwing me is that it's not consistent at all. temprature doesn't seem to matter, filament doesn't seem to matter, and it happens on both sides of the dock. I'm somewhere around 9 or 10k changes on this head, so nothing extreme compared to what some of you are running.
I popped the cover off and poked around a bit but honestly I didn't know what I was looking at. There's a small lever near the gear train that moves when the dock magnet pulls on it, and I noticed a tiny bit of wiggle in the wire attached to it that I don't remember being there. Could that little bit of play be enugh to cause flaky releases, or am I chasing the wrong thing? And if it is the lever, is there any fix that doesn't involve gluing something in a space the size of a grain of rice? I don't trust my hands that much.