Thumping Noise Under Duress
Hi. Your problem probably lies in the plastic transmission housing. This cheap piece of plastic has no business in a high priced mixer, as it has two important shafts that depend on the integrity of this housing for their bearing seats
Remove the top cover from the mixer. At the front top of the mixer is the trans. housing. Examine this housing carefully for cracks. If you find cracks, then you have new damage inside the mixer. If, when you replaced the three gears, I suspect that you did not discover the cracks in the trans. housing and reinstalled it after you replaced the gears, or you may have missed internal damage from the first breakdown.
When this cheap plastic part fails, it can destroy the worm gear, it's bearings and the bearing seats and possibly more.
Kitchenaid's replacement housing is made of metal. Kitchenaid markets these mixers saying it can handle bread dough. The ugly truth is they cannot!
You must open the unit up, remove and save the grease if it's relatively new. You must check every moving part in the mixer's transmission. You have to remove grease from these parts in order to find the damage. When you have the unit repaired, sell it!
I had the same problem with my mixer. I replaced all of the broken parts, and sold it. Since then, I bought a used Hobart N50 ( 5 quart), and an A200 (20 quart) mixers, both of which are commercial mixers. Both of these can handle heavy dough and they do so with ease.
Kitchenaid, to this date, have refused to recall these trans. housings, even though thousands of these cheap plastic housings have failed. Good luck with this saga!
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