While running, my KitchenAid classic makes a knocking sound. It seemed to be loose at the pin that joins the motor housing to the stand. The last time I used the mixer, the pin actually came half out of its hole. The mixer was brand new and has only been in use for a couple of months (6-8 uses total).
"Screws just fall out all the time, the world is an imperfect place." John Bender - The Breakfast Club.
I came across this site looking for the same answer. I tinkered with my KSM90 model and think I found the solution.
If the hinge pin is vibrating out of its slot, unplug the mixer and flip it upside down. (Removing the bowl makes it easier). You should see a screw centered over the hinge pin. Center the hinge pin and tighten the screw.
This should do it, although I tightened about every other screw on the machine before I found this one.
My pin came right out and I couldn't get it back in. I turned it upside down like someone recommended and loosened the screw, still couldn't get it to line up and go all the way through. I finally put a little cooking oil on the pin, turned the machine on it's side, and it went all the way through. Then I retightened the screw.
I have the same problem, but still can't get the pin to go all the way through. I tried oiling it as suggested above, but had no luck - it sill won't go any further than the hinge - I have tried from both sides. Until I get this sorted out, my expensive Kitchenaid mixer cannot be used.
Hahaha!!!! Yes, tightening the screw from the underside made the whole thing run as good as new!!! I thought that it was that the pin was worn out and that I would need to get a new one, so I took that as an opportunity to convince my wife that a Bosch mixer is better (since that's what I grew up using and my mom still has it 30+ years later.) So now we have a new Bosch and a runs like new KitchenAid!!!! Asi es la vida!!! :)
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General rule of thumb is, with electronics, if you hear something rattling or coming loose that shouldnt be get it worked on or looked at immediately before it causes more damage.
Since yours is still under the manufacturers warranty immediately contact them to see what the steps are under the warranty.
My sister had the same issue which was beyond the warranty it was only the matter of months before it died on here. this is something that cant be fixed by yourself I'm sorry to say...
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Try pushing the pin in from the other side, forcing it in is better than making the hole any bigger as a loose pin will allow head wobble when mixing. Get the pin thru the pedestal without the motor, then get the pin through the motor neck then put them together and get the pin thru both parts. You need to have the locking lever in the release position to do this more easily. Make sure the pin isn't damaged on the end. It shouldn't be damaged on both ends unless you've been abusing it.
You didn't say which model KitchenAid mixer you have. Assuming that it is a tilt-head, and that the metal portion of the motor housing joining it to the base did not break, the Service Manual can be had at:
There is a spring inside your mixer attached to the speed control switch and speed control arm, the spring can sometimes get caught on the slide bar that is just below it inside the mixer. The other reason is that the speed control switch plate in the rear of the machine (that the spring attaches to) vibrates the three speed adjustment screws out or in and the spring will pull the speed switch (control arm that you use to control mixing speed when using the mixer) back to the stir position after you try to turn the mixer off.
If it is a spring problem you will have to do a full tear down to get at the spring and either free it or replace it. If it is a problem with the adjustment screws on the speed plate, that can be handled at the rear of the machine and is twice as easy to get at but sometimes much more frustrating to adjust. There are "YouTube" videos on the internet that will walk you through the process of adjusting your speed control plate just Google "adjusting speed on kitchenaid mixer" I hope this helps. please let us know if it does and if you have other questions just post them here and we will "FixYa"
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.
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.
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
I think that the motor is still fine. Get a Copy of the Repair Part List from Kitchenaid.com. First thing I would do is to check the two Motor Brushes (one on each side of the Motor Housing). Make sure they are not worn out, and when inserted, they must both make contact with the Motor Coils. If even one of them is not in contact with the coils, the motor will not run. You can also remove the Motor Housing and visually verify that they are touching the Coils.
I don't have a direct answer for you. There are many things which could cause the noise from a beater simply hitting the bowl to internal gear problems. You did not say which model you have so take a look at the two Service Manuals linked below. One of these ought to cover your machine.