Openai/695aac28-9538-8011-823a-ed005c76baf2

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gpt-5-2

User: This is a filament sensor on a flash forge ad5x it’s been accidentally taken apart and now unsure how to put it back to…

This is a filament sensor on a flash forge ad5x it’s been accidentally taken apart and now unsure how to put it back together can you help?

Assistant: Yep, I can help 👍 — this is a mechanical filament runout sensor, and they’re fiddly but not complicated once you know …

Yep, I can help 👍 — this is a mechanical filament runout sensor, and they’re fiddly but not complicated once you know the order.

I’ll describe what each part does first, then the rebuild order so it makes sense.

What the parts are (based on your photo)

From left / bottom to right / top:

1. Two black plastic halves - These are the sensor housing (top and bottom). - One half has the microswitch soldered inside (the one with metal pins visible).
2. Two black round pieces - These are the filament guide rollers / bushings. - They sit in the filament path and help push against the switch lever.
3. Small metal spring (V-shaped) - This is the return spring that pushes the filament arm back when no filament is present.
4. Small silver metal clip (odd shape) - This is the retaining clip that holds the spring and lever in place.

How it works (quickly)

• Filament goes through the middle.
• Filament pushes a lever/roller.
• That presses the microswitch.
• No filament = switch released = printer pauses.

So we’re rebuilding a spring-loaded lever pressing a switch.

Reassembly – step by step (important bit)

1️⃣ Start with the bottom housing

Use the half that has the microswitch inside.

Lay it flat with:

• Microswitch at the top
• Filament path running front to back

2️⃣ Fit the two black round rollers

• They sit in the circular recesses in the housing.
• Their split side faces up.
• They should rotate freely.

These form the filament guide and the moving contact.

3️⃣ Install the spring

• The point of the V faces downwards into the housing.
• The two legs sit against the plastic posts near the filament path.
• This spring provides pressure against the rollers.

⚠️ This is the part that usually jumps out.

4️⃣ Add the metal retaining clip

• This clips over the spring.
• The hole in the clip aligns with the small plastic post.
• Its job is to stop the spring popping out while still allowing movement.

If this isn’t seated properly, the sensor won’t work reliably.

5️⃣ Check movement (before closing)

Use a bit of filament or a small screwdriver:

• Push through the filament path
• You should feel spring resistance
• You should hear/feel a tiny click from the microswitch

If it doesn’t click → something is misaligned.

6️⃣ Close the housing

• Place the top plastic half on carefully.
• Make sure: - Spring hasn’t shifted - Rollers stay seated
• Screw together gently (don’t overtighten – plastic threads).

Quick test (before reinstalling)

Once assembled:

• Push filament through by hand
• Pull it out
• You should clearly hear the switch click in and out

No click = printer will think it’s always out of filament.

If you want

If you can:

• Upload one more photo showing inside one housing half, or
• Tell me whether the switch clicks when open

I can sanity-check orientation and catch any subtle gotchas. These sensors are notorious for being rebuilt almost right 😅