If you bought this mixer less then 1 year ago, call KitchenAid at 800-541-6390. They have a "hassle-free replacement" warranty. They should ship you another mixer. I bought one recently and it died after 3 days of use. I called and they are sending me a new one. However, it is not comforting that these mixers fail so quickly. KithenAid use to be made a product to last many years. I assume the quality has declined. Good luck!
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Sounds like a worm gear problem to me, it's impossible for the motor (armature) to move far enough to not drive the gear. There are driving pins in the system from fuse gear to paddle.
1) in the fuse gear
2) inside gearbox above planetary joining shaft to bevel gear
3) through planetary and shaft
There is also one joining the little gear inside the planetary to the shaft, doubt you'd break that one though.
Sounds like what happened to my wife's mixer. There is one nylon gear in the drive assembly that is designed to break if too much load is put on the mixer. Like what can happen with dough or butter that is too hard/frozen. That is designed to save rest of the mixer. Sounds like you need to replace the KitchenAid Mixer Worm Drive and Pinion Gear Assembly. In our case, it was not the nylon gear that broke, but a small pin that is this gear assembly. By getting the assembly & not just the nylon gear, you cover more of your bases. I found a video on line that walks you through replacing the part. I also bought the part online. The assembly part, including shipping cost me $12.95.
First, you may want to adjust the mixer's speeds: 1. Loosen the lock nuts enough & Turn the 2 top screws clockwise until they cannot be turned anymore. Leave the bottom screw alone for now. 2. Use a dab of white paint or paper whiteout to mark the positions of the Phillips screws. 3. Plug in your mixer and Set the speed selector to "Stir". 4. Turn each top screw One full turn couterclockwise (alternating between Left and Right) Keep making one full turn at the time (for both left and right) until the motor starts running. 5. Put your hand near the Agitator shaft and allow it to brush your finger slightly. Use your watch or clock and start counting the number of times the shaft touches your finger in 60 seconds. The correct count should be 60 RPM (Rounds Per Minute). If it is less or more than 60, give each screw 1/4 turn counterclockwise or clockwise and start counting again. Now tighten both lock nuts. 6. Set the speed selector to "6" and turn the bottom screw either clockwise or counterclockwise to achieve a speed of 180 RPM.
For your reference, the planetary RPM's for the 5-qt. tilt-head Artisan Stand Mixer are as follows: Stir speed - 60 Speed 2 - 95 Speed 4 - 135 Speed 6 - 180 Speed 8 - 225 Speed 10 - 280
Second, if the mixer won't run: Remove the Control Plate Assembly (36), the Phase Control Board (39) and the motor Governor Assembly (35). Inspect for loose connections, burnt or damaged components. If they seem to look OK, re-assemble them and test the mixer. If the motor still won't run, then I might suspect a defective Phase Control Board (39).
When you are able to remove the paddle, feel the opposite side of the spindle. It should be smooth. The pin should not stick out the back at all. Carefully, tap it in until it is even with the spindle. That will fix you up, unless the pin itself is also damaged. If so, get a small file and remove any burrs from where the paddle mounts.
Fixed it!!! My mixer had the same problem. It was a hand-me-down...
Okay, so I lifted the head and looked down into the pivot where there is a screw (looking from the front of the mixer). I took a flat-heat screwdriver and turned it counter-clockwise. (It took quite a few turns, the screw came out a few millimeters.)
BUT when I lowered the head, hurray! No more paddle rubbing against the bowl! No more head jumping up and down! No more wobbling in the "locked" position!