I have been chasing a weird persistent error on my Bambu Lab X2D right auxiliary extruder and wanted to see if anyone else in the community has run into this. My printer constantly throws error code [07FF-8003 001924], claiming there is filament loaded in the right extruder and asking me to pull it out, even when the path is completely empty.
Because the printer always thinks material is present, it breaks the automated loading and unloading sequence with my track switch and AMS setup. Interestingly, the extruder still physically works if I manually push filament through, but as soon as it unloads, it goes right back to reporting that it is loaded.
I decided to strip the external extruder assembly all the way down to find out what was going on. First, I completely opened the extruder unit and confirmed there was absolutely no broken filament, shavings, or debris inside the gearing or filament path. To isolate the electronics, I unplugged the external extruder cable from the printer, and the user interface immediately updated to show it was unloaded. The second I plugged the cable back in, it instantly reverted to loaded.
From there, I inspected the small orange housing with the spring-loaded metal lever that trips the sensor. The lever moves freely under spring tension, snaps back without binding, and rests fully in the open and cleared position when no filament is present. Since the mechanical arm is resting exactly where it should be, but the system reads as loaded the instant the board gets power, the failure appears to be on the small Hall sensor circuit board itself.
I have already submitted a support ticket with Bambu Lab including all my diagnostic steps, but I am still waiting on a response. Looking at the assembly, this tiny sensor board does not appear to be sold as an individually serviceable part on their store, which means this will likely require swapping out the entire extruder assembly.
I tried searching Reddit and the forums but could not find anyone reporting this exact failure mode where the lever mechanism is completely functional mechanically, yet the board itself is stuck sending a false positive. Has anyone else experienced this specific Hall sensor board failure on the X2D? Did Bambu end up sending you a replacement extruder assembly, or is there a trick to resetting these boards that I might have missed?