Occasionally you may need to take an extruder apart for troubleshooting purposes. This is a simple process that will require no tools other than the 2.5 mm hex wrench you received with your MakerBot Replicator 2X.
How to Disassemble an Extruder
Unload any filament from the extruder. To run the script for unloading filament, go to the LCD panel and select Utilities > Filament Options, then select Unload for the extruder you wish to unload.
Once all filament is unloaded, switch off the power on the MakerBot Replicator 2X and unplug the power supply. Pull on the connector to release it from the power input port.
Unscrew the two bolts at the lower corners of the fan guard using your 2.5 mm hex wrench. As one piece, remove the fan guard, the fan, the heat sink, and the spacers. Keep these pieces assembled and move them out of the way.
Unplug the motor wire harness from the top of the extruder motor and slide the motor assembly out of the extruder. Your extruder may look slightly different from the one pictured, but the basic idea is the same.
The extruder is now broken down into its main assemblies. To remove any filament stuck in the thermal barrier tube, plug in the MakerBot Replicator 2X, turn it on, run the Unload script to heat the extruder and use a pair of pliers to pull the filament free.
While the video below is for troubleshooting, it does show how to disassemble part of the extruder assembly:
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