How frustrating! Was there a mixup at your dealer and they believe it was fixed by the service dept or could the service dept not fix it? I would want answers. They sell Babylocks, they should have a service that qualifies to fix this, or offers to send it out to Babylock for repairs. My thoughts would be the timing may be off due to trying to sew the 4 layers. With an incorrect needle on 4 layers could easily cause a timing issue. I have my mothers Brother VX 1120 that may have timing issues. She used it 2x before she had a stroke and couldn't use it. With the cost of the machine, I am debating if I should get it repaired, or simply purchase another machine similar to hers. Your Babylock is a good machine, I hope your dealer can check it out again for you. At least walk you through what the issues are.