Extruder Clicking... E3D Clogged?

Try 230 degrees? "2hrs" suggests temperature creep, resulting in some expansion up higher above the heat zone. 240 is also relatively high, for natural ABS no less (natural tends to = slightly lower temp.)

Only time Ihad this problem was when my e3d fan stopped worked. It would work but the wire was broken somewhere so occasionally it'd stop and sometimes an hour or two intot he print it would stop long enough to cause a clog.

So I changed the thermistor to type 5, and it seems to work just as it did before when it was "TEMP_SENSOR_0 6 //solidoodle patch".  Unfortunately, with 230 degrees, a cleaned out e3d, and some good natural ABS, the motor still clicks.  I'm going to try the stock hot end again to see if the problem is with the hot end or the electronics.  Would having the stock stepper drivers on the Sanguinololu be a problem instead of DRV8825's?

It doesn't click without filament.  Depending on the tension in the spring the filament will either strip or the motor click, so I doubt the bearing is to blame.  I don't feel like the alignment is very good, but the E3D wont go any further into the MK5.  I had to create a part to prevent the filament from bending after the stepper and before it enters the hot end, and without it, the filament bends before the motor starts clicking.

Will do in the morning!  Thanks for your help!  It never even crossed my mind to move it.  Is that 220 for ABS?

Well that drive gear is really tight!  Hex stripped before it could come off.  I then decided to try my old hotend from Solidoodle.  It worked just fine.  Not as quick to extrude as the e3d, but there was no clicking, and I didn't even need the little part I made to prevent the filament from bending between the drive gear and peek.

That is to bad (Hex Stripped) I hope you can fix that as I believe your real problem with the E3D was an Alignment issue.
I have an extra extruder motor and E3D all mounted to MK-5 That works if your interested in some kind of exchange?
I switched to the Bulldog XL and put a new E3D thinking I might want to switch the hole assembly from time to time.
Just drop me a PM I am willing to help you out if I can and I truly believe once you get an E3D running you'll wonder how you ever printed with out it.

Thanks, but I think I'll try to salvage the old extruder stepper and just buy a new drive gear.  I'd worry that I messed something up with the E3D rendering it useless.  Thanks for all your help!

I've been able to get set screws out in the past with a small flat head eyeglass screwdriver.

Yep!  it is definitely an alignment issue.  I tried printing without the accessory clip with the stock hot end today, and about 10 minutes in, it pushed the peek straight out the front of the MK5.  Thanks all!

Glad to hear you got it working.  Next time I strip out a small screw and need it drilled out I am just sending it to you.