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Possibly the fuse gear has failed, that is inside the gearbox and the first gear after the armature. It is made of plastic and designed to fail if the machine is overloaded.
The armature will not normally make a knocking noise, even on low speed it is turning at hundreds of revolutions per minute so you will only get a whirr not a knock. Most common knocking is the plastic fuse gear missing a tooth or two. That is the first gear driven directly from the end of the armature. What you should have done is break it down slowly while always keeping it together enough to run it with one component less each time. Remove planetary.....run it. Split gear case apart....run it. That sort of process will give you a clue where you need to be looking for the fault.
you have an internal gear problem if you continue to us it you can damage other gears and increase your repair parts needs. go here to get a parts list for your model and start the tear down to find the culprit http://www.kitchenaid.com/customer-service/manuals/ then order your part from eBay or several site on the internet that sell KA parts like "Seneca River Trading or mending shed" then re-assemble. Parts will be anywhere from $6.00 to $20.00 USD. hope this helps
Something is out of balance, the front or rear bearing sounds like the culprit. the rear bearing is a relatively easy fix from the rear of the machine the front bearing is a little harder and will require a full tear down,
There is a sometimes problem that can fix a bearing problem that is actually not a bearing problem but a loose nut problem. At the rear of the mixer after you have removed the rear end cover get down to eye level with the rear of the mixer look to the right and left of the copper and black plastic speed switch plate and you will see a 3/8 nut on each side of the rearing housing, these sometimes get over tightened or come loose, you need a nut driver to operate them. tighten them up and turn on the mixer if there is a noticeable change in the pitch or sound of the mixer or the knocking gets worse turn them back the other way and listen again, if the knocking goes away then it was the nuts, it is only a sometimes fix, but it can be the problem, if it is not the bearings i would generally start my fix by going to the gears first, The worm gear can be going and that will also take a tear down to fix but easy to do, you will need a new gasket, grease, a new worm gear and plenty of paper towels, it's messy. how long has it been thumping? how old is the machine? the worm gear fix has several really good you tube vids for this, just type in broken kitchenaid and you will get several, please let us know if this helps
It has been my experience with knocking kitchenaid is one of three reasons all related to the speed control of the mixer1 speed control board adjust speed screws2 speed Phase control board, needs replacing3 The motor governor behind the speed control board needs replacing Speed board = $9.00Phase Board = $20.00Governor = $10.00Your time + one week for ordered parts asnd one hour to remove and replace.
all work is performed at the rear of the mixer and you need only a phillips #2 screwdriver, a pair of needle nose pliers, an 11/32 open end wrench (you will need this to adjust your speed control board after new install) and that's it. easy work all remove and replace. Oh! make sure that you pit some thermal paste behind the phase control board to avoid burn out.
But!!! before you buy parts and do all that, try adjusting the speed contol board first. Go here for a parts list for your model.
if after you tune it you still get the knocking then use the parts list to order parts. two good parts sources are goodmans.com and mendingshed,com, they are reliable and have the parts in stock.
It sounds like the Worm Gear is going out. The faster the motor runs,
the more damages the Center Gear is grinding away the teeth of the
Worm Gear. Things start to slow down, and eventually they will come
to a halt. It's time to replace the Worm Gear. Also make sure to use
new fresh Kitchenaid Food Grade Grease with the new replacement.
we need a make and model number
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