Let me update on this one. I changed the needle. I inspected the old one, and it looked no different than the new one, not that I could see without a microscope or magnifying glass.
I adjusted the upper thread tension.
I sewed for a little while with it today, then BOOMIt started up again! :(
I tried calling brother twice and left voicemails twice was promised I'd be called back twice.
Now, I'm trying to find out something online...it's a joke! It must be!

As I have already said.... it could be a piece of thread that is hiding... you will need to unscrew what you have to and have a look..... it has happened to me several times and it ALWAYS was a piece of thread about 2 inches long.....

Try a new needle and then adjust your tension. Worked for me.

I will try it. I didn't realize you meant to unscrew things. I haven't messed with the machine for a few days, since I got my other one back.

Have you changed the brand of thread that you are using? I have a Janome that does not like Coats and Clarks thread at all. It will bind up so thight that nothing will make it move. Using canned air will sometimes just push the lint further into the machne. it is very time consuming, but take a small brush and a tweesers and start looking inside to see what is jammed into the back of the bobbin case area.
Try a new needle, different brand of thread in both the bobbin and top thread and see what happens. Good luck. :(
nannapat

Hi, Pat. I have tried many different brands/kinds of thread. Thanks!

Miranda...I was reading the manual that came with my new brother I just got for Christmas, and it said that if the bobbin case is scratched it can cause this very problem. It suggest ordering a new bobbin case and replacing it. Not sure if this is the problem with your or not...but maybe (and I know you had problems with them before but...) if you called them they could give you more info if this is the problem or not.

I have a Brother and this happened to me. I took it apart and there was thread pieces and dust from the thread down in the bobbin case. I used the little brush and a vaccum to clean it out. It worked great. Hopefully that is all it is. Maybe it is just in far enough you can't see it with the naked eye. Good luck!

hey Judith thats what I was going to suggest...I have the same brother as she does without the probs but if I have been sewing fast or for long periods if I move it back and forth I dont have the problem :)

It could be. I haven't tried anything else since I got the "new" one back, but the new one messed up a bunch yesterday. I guess family should not look for handmade gifts from me this year. :(