Z Height Calibration Issues

Had a nasty clog that ate the left hot end. Replaced the dual extruder while I waited for parts, and now when I put the dual back on and ran ALL of the calibration routines successfully, I have to lower the z-height offset at least .4mm to get a decent first layer - before the clog I had INCREDIBLE first layers with no tweaks needed.

I have done the following in this order:
Calibrated the sensor
Auto-leveled the bed
calibrated the z-offset
calibrated the x/y offset
did the x/y calibration verification.

All that works fine and appears to have nice first layer, but as soon as I do a normal print I have to lower the z-offset almost to the max.

Almost to the point that I am going to do a full manual bed level…

Thought’s before I take on that pain?

Thank you!

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Check the magnetic sensor on the back of the DX, it has an adjustment screw that’s accessible by taking the cooling shroud on the bottom off, make sure it is offset 1mm from the left nozzles tip and level, mine was loose during shipping so I had a similar experience.

Here’s some reference photos.


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