I'm sure most of us have been in the same spot at one time or another. You didn't mention your model number which might be a help to others here. Did you try changing the needle? I'm sure you have as it seems you have tried most everything else. I suspect the timing is off....and for me that means a repairman. Depending on the amount of money you spent on the machine, and the cost of the repair...well it might be time for a new one. Most new cheaper models (big box or some Walmart specials) are made to only last a few years and can't be repaired and thus have to be replaced...which is why many of us here stick to the older model machines and look at the trade ins when out machine shopping. Ask for an estimate before you agree to any repairs. That would be my best advice. Budster

I am not a sewing machine expert, but I do make a lot of quilts. Occasionally, like everyone else, my machine does what you are describing and usually a quick cleaning or re-threading fixes the problem. It is not normal for a 5-6 year old machine to be doing this so it sounds like it time for a trip to a service place. It's worth it to reduce the stress it's causing. Like the previous poster said, get an estimate so you can decide if you want to repair or replace!

You said it doesn't matter if it's the top or bottom thread. Do you mean it does it with both? From a trouble shooting perspective it does matter which it is so if it's one or the other it would help to know that.

Is this machine new to you or have you had it a while? Did it ever work OK or has it been doing this as long as you've had it? If you bought it used, and it's never worked for you, then this might be why the last person got rid of it! But if it used to work fine for you, then it can almost certainly be fixed.

What's the model? There may be others here with similar problems.

Try posting this on the quilting forum too be cause there are lots of quilters with Brother machines and they may be able to help if they know the model.

Good luck!

This might be a really dumb question, but have you checked the thread? Is it high quality, is it really old, anything like that?

I learned this the hard way myself- rayon thread and my machine do horrible things together.

been there too, even on good machines. try cleaning out the bobbin area and keeping it clean also, I have found that my machine can sew a lot faster than the thread can handle, especially the cotton covered polyester. plain cotton thread or plain polyester works better. Also if I slow down it helps especially on button holes.

If it's like my brother the silver bobbin casing has a "screw" on the side. You have to turn the "screw" which is the bobbin tension. Good Luck!

How are you getting along with your machine? Did you find a replacement or get it working right?

With me, I enjoy both old and new machines. Old ones are beautiful and solid and reliable, while new ones have awesome features that make sewing a breeze. It seems like you have tried everything I would have thought of for that problem. Hope you can get it worked out.