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Thread shredding - one direction only


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I've been using my Egyptian Eye Circle Lord board - stitches perfectly going across the quilt from right to left  (back of machine), but when I bring it back on the next line, the thread is shredding - not all the time.   I've changed out everything in the thread path except the tension guide - the shred/break seems to be happening at the needle - beyond the pigtails (which I've replaced).   I've checked the needle plate to see if there is a burr there and didn't find any (used emery thread just in case ).  Also, I replaced the bobbin case as well.  

Thanks for any suggestions on what to do next.  I've had Schultzi since 2009 and have never had any issues like this.   

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Changed out the needle several times, too.   I'm using a 4.0 with SoFine.  Thought maybe a batch of bad needles so opened a new package.   I'm thinking now, perhaps I'll have to look into taking out the hook finger and bobbin basket out and check them for burrs.   I haven't seen or felt any, but that certainly doesn't mean there isn't one somewhere there.  Just seems strange that the thread only shreds going back - when there is the most flex on the needle.  

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