Here's my current gcode, I also lowered my printing temp to 190 which helped a lot. This is for an mk2, so probably some adjustments needed for yours. ; Auto generated 3D Chameleon Tool Change GCode for PrusaSlicer ; - 3D Chameleon Tool T{next_extruder} - ;begin switch from extruder {previous_extruder} to extruder #{next_extruder} M117 Unloading Tool T[previous_extruder] M82 ; turn absolute distances for the extruder ; unload extruder {previous_extruder} G92 E0 ; go to holding position to unload the stock extruder G0 X106.7 Y213.4 F2000 ;   <<-----  EDIT THIS LINE TO SET THE INITIAL LOCATION OF THE BUTTON ; if this is the first load, then don't unload M109 R190 G91 ; move to relative mode M82 {if previous_extruder>-1} M109 R190 ; set PLA temp and wait ; cool (and size) in 1.8mm tube G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F600; slowly allow it to cool G0 E1 F2000 ; blob elimination ; back to tip size G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F600; slowly allow it to cool G0 E1 F4000 ; blob elimination G0 E-10 F4000 ; quickly retract the filament to shape it G0 E1 F4000 ; quickly ram the filament to shape it G0 E-10 F4000 ; quickly retract the filament to shape it G0 E1 F4000 ; quickly ram the filament to shape it ; back to 1.8 constriction G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F100; slowly allow it to cool ; turn the fan off ;M107 ; this printer has the fan in the way, so turn it off ; retract it back out of the extruder G92 E0 G0 E-70.5 F2000 G92 E0 G0 E-30 F2000 G92 E0 ; ok - out of extruder - press button to remove it all the way G91 ; move to relative mode M82 ; NOTE: All button presses following this point are relative to the point above.   ;       They are always 3mm short of the X and Y axis and move +3mm to press the ;       button on either axis. They end up moving back -3mm on each axis after it. ; press the button 3 times to get back to the active extruder G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2; wait for it to happen G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2; wait for it to happen G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2 ; wait for it to happen ; ok - select direction to pull filament out G0 X3 Y3 F2000 ; press the button G4 P3500 ; dwell for 3 seconds {if previous_extruder>1} G4 P2000 ; dwell for 2 more seconds seconds {endif} G0 X-3 Y-3 ; back off the button ; now press and hold for 8 seconds to let it unload G0 X3 Y3 F2000 ; press the button G4 S10 ;             <<---- INCREASE VALUE (S = Seconds) TIME IF IT DOESN'T UNLOAD FROM THE Y ADAPTER G0 X-3 Y-3 ; back off the button ; we skipped to here if it was extruder -1 {endif} ; load extruder #{next_extruder} M117 Loading Tool T{next_extruder} ; always reset to extruder 0 G0 X3 Y3 F2000 ; press the button G4 P1300 ; dwell for 1.3 seconds G0 X-3 Y-3 ; back off the button G4 S3; wait for it to happen ; press the button for each extruder (1,2,3) {if next_extruder>0} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1; wait for it to happen {endif} {if next_extruder>1} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1; wait for it to happen {endif} {if next_extruder>2} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1 ; wait for it to happen {endif} G4 S1 ; wait just a little longer ; load the filament G0 X3 Y3 F2000 ; press the button G4 P3500 ; dwell for 3 seconds {if next_extruder<2} G4 P2000 ; dwell for 2 more seconds {endif} G0 X-3 Y-3 ; back off the button ; now press and hold for 8 seconds to let it load G0 X3 Y3 F2000 ; press the button G4 S10.1 ;           << -------   INCREASE THE S10 (S = Seconds) VALUE TIME IF IT DOESN'T LOAD INTO THE STOCK EXTRUDER - This should match the above unload time G0 E45 F1500 ;      << -------   ADJUST THE E50 VALUE TO STOP IT RIGHT AFTER IT LOADS INTO THE STOCK EXTRUDER (50mm is the default) ;                ADJUST THE F2500 TO MATCH THE SPEED OF THE FILAMENT FROM THE 3D CHAMELEON ;                NOTE: This defaults should work, but you can always tune them to be perfect. G4 P600 ;          This is just a half second extra reloading time... just to make sure G0 X-3 Y-3 ; back off the button G92 E0 ; now press it again to let go of the filament G0 X3 Y3 F2000 ; press the button G4 P400 ; press for 1/4 of a second to move to next G0 X-3 Y-3 ; back off the button G4 S1 ; wait for it to happen {if next_extruder>2} G4 S1 ; wait a little longer for it to happen {endif} G90 ; move back to absolute mode M83 ; but make sure the extruder stays in relative ; reload filament all the way into extruder G92 E0 G0 E1 F2000 ; <<<<<----------- EDIT THIS DISTANCE TO FINE TUNE THE FILAMENT LOADING TO STOP BLOBBING OR UNDEREXTRUSION G92 E0 M83 ; turn relative distances for the extruder M117 3D Chameleon Tool T{next_extruder} M109 R200

Yup I'll grab this tomorrow and send it over! Do you have the mk2 or mk3 version?

Here is my final tool change g-code that has worked really well. ; Auto generated 3D Chameleon Tool Change GCode for PrusaSlicer ; - 3D Chameleon Tool T{next_extruder} - ;begin switch from extruder {previous_extruder} to extruder #{next_extruder} M117 Unloading Tool T[previous_extruder] M82 ; turn absolute distances for the extruder ; unload extruder {previous_extruder} G92 E0 ; go to holding position to unload the stock extruder G0 X106.7 Y213.4 F2000 ;   <<-----  EDIT THIS LINE TO SET THE INITIAL LOCATION OF THE BUTTON ; if this is the first load, then don't unload M109 R190 G91 ; move to relative mode M82 {if previous_extruder>-1} M109 R190 ; set PLA temp and wait ; cool (and size) in 1.8mm tube G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F600; slowly allow it to cool G0 E1 F2000 ; blob elimination ; back to tip size G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F600; slowly allow it to cool G0 E1 F4000 ; blob elimination G0 E-10 F4000 ; quickly retract the filament to shape it G0 E1 F4000 ; quickly ram the filament to shape it G0 E-10 F4000 ; quickly retract the filament to shape it G0 E1 F4000 ; quickly ram the filament to shape it ; back to 1.8 constriction G0 E-36 F4000 ; quickly retract the filament to shape it G0 E-10 F100; slowly allow it to cool ; turn the fan off ;M107 ; this printer has the fan in the way, so turn it off ; retract it back out of the extruder G92 E0 G0 E-70.5 F2000 G92 E0 G0 E-30 F2000 G92 E0 ; ok - out of extruder - press button to remove it all the way G91 ; move to relative mode M82 ; NOTE: All button presses following this point are relative to the point above.   ;       They are always 3mm short of the X and Y axis and move +3mm to press the ;       button on either axis. They end up moving back -3mm on each axis after it. ; press the button 3 times to get back to the active extruder G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2; wait for it to happen G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2; wait for it to happen G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S2 ; wait for it to happen ; ok - select direction to pull filament out G0 X3 Y3 F2000 ; press the button G4 P3500 ; dwell for 3 seconds {if previous_extruder>1} G4 P2000 ; dwell for 2 more seconds seconds {endif} G0 X-3 Y-3 ; back off the button ; now press and hold for 8 seconds to let it unload G0 X3 Y3 F2000 ; press the button G4 S10 ;             <<---- INCREASE VALUE (S = Seconds) TIME IF IT DOESN'T UNLOAD FROM THE Y ADAPTER G0 X-3 Y-3 ; back off the button ; we skipped to here if it was extruder -1 {endif} ; load extruder #{next_extruder} M117 Loading Tool T{next_extruder} ; always reset to extruder 0 G0 X3 Y3 F2000 ; press the button G4 P1300 ; dwell for 1.3 seconds G0 X-3 Y-3 ; back off the button G4 S3; wait for it to happen ; press the button for each extruder (1,2,3) {if next_extruder>0} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1; wait for it to happen {endif} {if next_extruder>1} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1; wait for it to happen {endif} {if next_extruder>2} G0 X3 Y3 F2000 ; press the button G4 P400 ; dwell for .3 seconds G0 X-3 Y-3 ; back off the button G4 S1 ; wait for it to happen {endif} G4 S1 ; wait just a little longer ; load the filament G0 X3 Y3 F2000 ; press the button G4 P3500 ; dwell for 3 seconds {if next_extruder<2} G4 P2000 ; dwell for 2 more seconds {endif} G0 X-3 Y-3 ; back off the button ; now press and hold for 8 seconds to let it load G0 X3 Y3 F2000 ; press the button G4 S10.1 ;           << -------   INCREASE THE S10 (S = Seconds) VALUE TIME IF IT DOESN'T LOAD INTO THE STOCK EXTRUDER - This should match the above unload time G0 E45 F1500 ;      << -------   ADJUST THE E50 VALUE TO STOP IT RIGHT AFTER IT LOADS INTO THE STOCK EXTRUDER (50mm is the default) ;                ADJUST THE F2500 TO MATCH THE SPEED OF THE FILAMENT FROM THE 3D CHAMELEON ;                NOTE: This defaults should work, but you can always tune them to be perfect. G4 P600 ;          This is just a half second extra reloading time... just to make sure G0 X-3 Y-3 ; back off the button G92 E0 ; now press it again to let go of the filament G0 X3 Y3 F2000 ; press the button G4 P400 ; press for 1/4 of a second to move to next G0 X-3 Y-3 ; back off the button G4 S1 ; wait for it to happen {if next_extruder>2} G4 S1 ; wait a little longer for it to happen {endif} G90 ; move back to absolute mode M83 ; but make sure the extruder stays in relative ; reload filament all the way into extruder G92 E0 G0 E1 F2000 ; <<<<<----------- EDIT THIS DISTANCE TO FINE TUNE THE FILAMENT LOADING TO STOP BLOBBING OR UNDEREXTRUSION G92 E0 M83 ; turn relative distances for the extruder M117 3D Chameleon Tool T{next_extruder} M109 R200

I haven't put this on Thingiverse yet, but I ended up adding a mount for the Y adapter right above the extruder to help it feed straight in, the curve in the PTFE tube was causing too many issues: https://www.tinkercad.com/things/eUyM4r886xa?sharecode=HKTSRXTApmLUHkZWgD9UvxB9G5bmKUVesuJvC1HORNc Also, here is a pic of where I put my switch with some 3m tape, will design a part eventually but this was the quickest and easiest solution. Also a pic of how everything looks with the extruder mount.

SUCCESS

Would that be M109 gcode? Where in the code block should that go?

Hopefully I dont jinx it, but I lowered my printing temp down to 190 for all filaments and getting a lot less stringy pieces getting stuck in the Y adapter. Seems to be helping and its made it further than it has any of the other prints.

When it works its working great, then it will miss a step and fail to load it all the way.

The tip has looked pretty good but let me run another print to catch it in the act again and grab some pictures. It feels like most of the time the issue is between the hand off from the y adapter and the extruder.

I continue to have consistency issues, filament gets stuck and fails to push all the way into the extruder, starts to grind away the filament and then will even fail to pull it back out at some point. Is there anyway to improve grip, dual gears, or anything that could be done?

hahaha well that'll do it, they must have been barely in originally and worked for a bit. Thanks!

Yup I did move the motors and the problem stays with that one cable, not a motor issue. Just to confirm the red and black cables here should be disconnected?

Things have been going much better after making those changes, until today. It seems something with the control board is bad, I've tried cycling power and no changes. If I swap the stepper to the other cable and simulate extrusion it will rotate fine.

The first 75mm load it does when grabbing the filament gets it so far in that the actual load to the nozzle of 53mm (measured from tip to gears) just dumps out way too much. So either that initial grab is too high or the load is too high?

That position is where its at during all the load/unload commands

Ahh ok will give that a shot, though right now these settings are working pretty good. Only big issue is the blob on load, which i turned this down (was at 75mm initially) and adjusted the load distance and it has helped. G0 E20 F1500 ;      << -------   ADJUST THE E50 VALUE TO STOP IT RIGHT AFTER IT LOADS INTO THE STOCK EXTRUDER (50mm is the default)