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Upper Thread Error

I am trying to embroider on my Brother Innovis 4000D and I keep getting an error "Check and rethread the upper thread." I have rethreaded changed the bobbin (and bobbin case) changed hoops and stabilizer and replaced the needle. I still get this message and the few stitches it does manage to embroider in between messages, are a mess on the back side. The upper thread is making very loose loops on the bottom side of the design. Any suggestions?

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  • Wmctk2 Oct 23, 2007

    Thank you for the suggestion. I tried threading with the presser foot up, but still no luck. The pattern that I'm trying to sew is a Disney pattern that I have sewn many times before without a problem.  It seems to really have trouble with a running stitch, the stitches are extremely loose on both sides. Anyone other suggestions would be greatly appreciated!

  • Jillt Dec 08, 2007

    I have the same problem on my brother innovis 4000D. When it is good it is very very good but goes through regular patches where I get this birdsnest of loose (upper) threads looping on the underside. And I mean a couple of centimetres of loop not a few millimetres.



    Smaller needles help, but are not a cure. My machine is still under guarentee and is going back into the shop to see what they can do. I have tried new needles, defluffing, different bobbin threads, tension etc etc. yet just now it is sewing 'tigger' on felt and it looks georgous. five minutes ago it was looping almost every time.



    As far as I can see it seems to occur when starting sewing and it is as if something doesn't 'catch' at the beginnning. If that goes OK the rest does, otherwise I can have this problem and several false starts.

  • Vivienne Bahr Sep 29, 2012

    My 4000D had the same problem, I took it back to the shop & they thought it would be some fluff or thread caught in the sensors. I will be picking it up after the weekend & if the technician has found that is not the problem, I will let you know. It is definitely not a job for an amateur to try & fix.

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I just posted this under another Brother machine...mine is a se 350 but, might be the same problem!! Hi....I also kept getting the check and rethread upper thread message, I'd sew about 15 stitches and it'd stop. Here's what I did. On the left of the machine, in the back there is a screw....loosen that screw, take cover off, then lift straigt up and out on the cover that has the 3 on it in your threading seqence. Next, I started inspecting and cleaning the thread route from top to bottom. Lo and behold....I get to the place where you come down the front of the machine and turn to go back up and I spot a little slice/cut in the plastic piece so, when I was threading the machine I guess I was pulling it to far to the left causing it to wear a little slice/cut in that piece....so, I finished cutting it off with a utility knife, used an emery board to smooth it down, put the covers back on and it works GREAT!!!! Who would've ever thought that it'd be so easy and save me a bunch of money!!! I sure hope this helps someone.

Posted on Jan 07, 2013

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There could be thread caught in the tension disc in the top of the machine you can get the cover off to clear the thread but it is a bit tricky to get back on

Posted on Dec 06, 2007

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