The mixer switch will only work on high (level 3). I have checked the internet and this seems to be a relatively common problem. However, I have not been able to find a solution. Do you have any ideas?
Mine did the same thing. I found the ball bearing inside the switch had fallen off. Put it back on and it works like new!
Pull the mixer case apart. Push in on the seam in the front and back and it will pop open after you remove the 1 screw. Pull the switch apart. There is a spring inside the top part of the switch and a small (1/8") ball bearing should be on top of the spring. Chances are, it has fallen off. Find it and stick it back on the spring while holding the top part of the switch upside down. Put the mixer back together.
I just fixed mine. My daughter dropped it (again) and speeds 2 and 3
failed to work so I disassembled it and found a broken center terminal
on the power transistor. I saw a fine crack so I soldered it. I also
added much needed strain relief to the heat sink. It works fine now.
This is a poor design. The power device has a heat sink attached and
there is no strain relief so the transistor can move back and forth at
least 3/8". For a tool that sees a lot of vibration and shock, this
heat sink should be tie strapped or have hot melt glue to prevent
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Something must be broken if the motor is turning and the planetary is not. It will be one of the following, we will start from the first point of contact with the armature
1) Worm gear broken (fuse gear) you say no teeth broken
2) Worm gear not broken but whole unbroken plastic part not gripping aluminium boss
3) Pin through worm gear broken or missing
4) Pin through centre (or bevel) gear broken or missing
5) Pin through small gear in planetary broken or missing
6) Pin through planetary hub centre shaft broken or missing
The most common ones in order of likelihood are, 1, 2, 3 and 6
The leaking grease has very little to do with it not going, remove the chrome drip ring (yes it's called a drip ring, it is used to catch most of the drips) and clean it out & wipe around the planetary. The oil is separating out of the food grade grease due to age or lack of use or both. Remove & check the carbon brushes under the side caps on the motor. They are keyed so will only work when installed the correct way. You may find the brushes worn out and in need of replacement. Observe which way they come out, one corner is ground off and that is the key. If that is not the problem then you will need to look under the back cover, sometimes there can be a broken or loose wire there.
Check for broken wire under back cover. Check operation of switch contacts on black speed control plate. Check carbon brushed under black screw caps on the sides. The brushes are keyed, they only work one way.
Don't open up the "works" part of your mixer if it is still under warranty!!!! If the policy hasn't changed, you'll void the warranty by doing that.
KitchenAid has one of the best user forums of any company as far as I'm concerned. The participants are great and the monitors are exceptional (some of the best problem solvers you are likely to run across). You may find your experience already has a thread, if not, post it. I checked in and they seem to have added a video library that has some of the topics I've seen posted at this site. Tell them "mnme" sent you. (LOL) http://www.kitchenaidconversations.com/
You might have someone repair it for you; here is a place that charges a flat fee of $69.95 and thats including the return shipping. Check 'em out:http://www.marbeck.com/repair_mixer_kitchenaid.html
The speed controller board sounds like the right direction but it hard to know if that is the issue until you install a new part. This is a known issue as far as I have heard around the internet. You might give KA a call and see if they can help; all they can say is no. I have heard they revised the part to fix the problem; my brother had a couple of boards replaced on his pro model and now it seems fine. Good luck!