SOURCE: bobbin thread not catching
Whenever you see loops on the underside of the fabric something is snagging the thread. the biggest culprit is burrs on the hook. the hook is what goes round and around the bobbin. The reason for burrs on the tip of the hook areseveral
ONE ...is by helping the fabric through as the machine is doing the sewing which directs the needle too close to the hook thus scarring the smooth surface of the hook and potentially breaking it off and the needle too. You must allow the machine do it on its own and only guide the material.
TWO...Sometimes if you are sewing s-t-r-e-t-c-h-y double knit material the material calls for a ball point needle. I have gotten good results with the Singer brand YELLOW BAND needle.
Three ... The hook could have gotten out of timing. What this means is that the hook is not meeting the needle on the top edge of the eye of the needle. You yourself can check this out by removing the bobbin (or shuttle, cassette). Install the needle flat side to flat side of the mounting rod and all the way up. By slowly turning the handwheel on the right slowly and watching that the eye of the needle is just below the hook on the upward swing of the needle and that they both meet dead center. This when you need to take it in to a repairman. FrankIy I don't like to advise this because of unscruppulous practices. My boss used to call me a virgin Mary because I wouldn't ripp-off the customers. Anyway at this time you can also check the condition of the hook carefully looking for nicks and scratches on or around the tip of the hook. If there is damage present you can file this down with a very fine emory board or by using a strip of 400 to 600 grit sandpaper as if your were buffing a shoe. If the hook is removeable by unsnapping the snaps on either side its easier to buff. Anything courser may contibute to the problem. If the paper won't remove the damage you may need a whole new hook. If its not removeable you will have to take it in to have it installed.They have to time it properly.
Four...The two disk that you mentioned also has a spring. That sping is there to pull up those loops. If the disks are full of lint from the thread going through. the clups of lint won't allow the discs to apply tension on the thread and thereby having tightened the tension so much that that spring is not working properly.You can clean the discs by raising the foot which opens the discs. With a long narrow pick pull out all that lint without scatching the discs. Check closely that the the thread goes across the top of the machine down through the discs pull up snug so the spring engages,through the take up arm,in the two thead guides, then into the needle front to back or right to left, if it is a side loading bobbin. Now the tension will work properly!
TESTING : Move the TENSION dial to mid point of the dial usually 5. This is your starting point.
With two layers of fabric ( not stretchy) and with a regular needle, set stitch length at about 12 per inch on the dial. Now sew about six inches. Raise the fabric and look at the results. Do minor adjustments necessary on your tension dial up 6...7.. if loose on the bottom 4...3..2 if loose on top.
If you did all the steps above those are the steps a repairman performs and charges $75 except me I used to charge $10 .
Brother machines are good quality it is those hidden gremlins that make a fun hobby frustrating when you don't have someone to turn to without having to shell out cash! Its been a pleasure!
jravenus
SOURCE: bobbin won't thread
If the hook is not spinning then it needs a gear job which will cost you anywhere from $150 to $250 depending on who you take it to. This machine has four plastic gears which should all be replaced, don't just replace the one that is stripped as the others will go bad soon since they are the same age.
You may be lucky in that something has only come loose, but if they are the original gears then most likely is that they need to be replaced.
Good luck!
SOURCE: Timing problem on Rex commercial blind stitch
retime your hook with relation to your needle the hook is slightly out of time causing it to "slip the loop" the hook should hold the loop until the needle retracts forming the chain
SOURCE: lower thread problem
are you still looking for an answer? if so I can help but I don't want to type all day if you already fixed it.
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