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It could be a different gear that is stripped in the mixer. There is also the chance that the gear that was sent you was damaged before it was put in, we do see chipped gears come from KitchenAid every once in a while. The best thing to do would be to take apart the mixer, clean the grease off the gears, and carefully inspect each one for chips or gouges in the gears.
From the sound of this issue I would have to say the adjustment screws are defective or stripped Normally inside the housing the screw acts like a clamp against the paddle shaft pinching it at the desired height of operation Because Kitchenaid makes alot of their housings from a die cast aluminum tin Mix its easy for the manufacturer to insert the screwed and strip threads causing this issue Replacement of the product at this point is your Only Option for safe Operation of any kitchen appliance.
Sounds like a problem we had years ago. We put too much pressure on the motor by mixing a very thick dough for cookies. It stripped the "gears" and couldn't be used on slow.... it would instantly go to the fastest speed. We had to take it to a reputable appliance store that does repairs on KitchenAid products. I'm still using mine and that has been 15 years ago. It still works great!!
the unit sounds like the drive unit is stripped. if the planitary unit is spinning that gear is ok but the one below that is stripped. which is the one that spins the beater. Usually the professional lines are covered under a 2 year warranty. where as the others are a 1 year. I would contact kitchenaid first and see if your product is covered for replacement. they are really good about replacing faulty units. if not the unit can be repaired. It is a simple process and you can buy the parts off kitchenaid. usually the parts come with instructions as to how to replace them but if not repost to me and ill get you the directions on how to replace it.
It sounds like the nylon gear is stripped out. It is a rather easy to replace and also inexpensive. A gentlemen posted a step by step site to replace the gear. The link is http://www.neilcrockett.com/mixer.htm Good Luck
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