Have you checked the health of the extruder stepper motor and really examined the filament path? I’ve had two weird issues with my direct drive extruder, one was the filament had work a small groove into the metallic tension arm which would catch the filament and cause it to jam. The other issue was a stepper motor that got some debris in it and would bind up intermittently. Not sure if your printer has a bowden setup, but it’s something new to check out.