AMS feed problem?

Having an AMS issue which is driving me insane, hopefully someone can shed some light:

A week ago my P1S started to misbehave, mid-print it just stopped spewing out filament and did a couple of hundred layers just shooting out hot air before alerting me that the job was done, no errors.

Messed around a bit, nozzle was a bit claggy, cleared that, filament sensor works as it should, manually extruding worked so got a couple more prints out of it.

Then the problem happened again, filament stops extruding halfway through a print even though filament is in the top of the extruder. More messing, maybe extruder gears a bit worn - tested by removing bowden tube from top of the extruder and just poking filament in there - works fine, many prints done by telling bambu slicer to use external reel. Bowden connector on top seems to have lost it’s spring so replaced entire extruder in case gears were not helping. Also replaced hotend. Test prints done by poking filament into top of extruder, all good.

Replacing the bowden tube is when the issue occurs again - AMS seems to be working, it will feed filament in until it hit the filament sensor (with bowden removed it will feed 10 feet into air then wind it back in so a blocked tube is not happening). Connecting the tube to the extruder just won’t work - AMS feeds it in, filament sensor clicks open, sits there for 10s, AMS reels it back in 3 or 4 times then it gives up with "unable to feed filament, entanged, stuck spool, check PTFE etc.

So I think I’ve ruled out extruder, hot end, filament sensor, blocked tubes but this is no getting anooying, any ideas please?