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Thank you. I recently replaced that gear as well, and the problem has gotten a bit better. I'll be sure to check everything you just mentioned.
I tightened the tension arm and now it's clicking when it reaches a piece of filament that isn't extruding fast enough. So I think that means it's an issue with the hotend not heating the filament fast enough. I'll check the friction of the mod though just to be safe, and I don't think I ever calibrated my E-steps, so I'll have to do that.
Adjusting the tension arm seems to have helped a lot, so I think you're on to something.
Yeah you don't want the arm TOO tight or you just create another friction issue. I generally find if you have a very consistent under-extrusion then it's likely the E-steps, but if the issue seems more random (some layers are great, only certain corners are bad, etc) that it comes down to friction somewhere in the line. Good luck!