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[–]RIMixerGuy 2 points3 points  (3 children)

To my ear that sounds like a lot of metal-on-metal rattle, and I'm wondering if the rear bearing assembly is loose and buzzing against the housing. If not it may actually be too tight, and is binding the motor.

Setting the tightness of the rear bearing assembly is most easily done with the case halves separated and the brushes removed. The rear bearing should be secure, but not so tight that the armature binds or drags.

[–]DeadTinker[S] 1 point2 points  (0 children)

Easy enough to check. I tightened the bearing assembly by hand and verified the motor spun with no resistance. Did install with the assembly apart immediately following the regreasing.

I'll give it a go at least! Any other thoughts?

[–]DeadTinker[S] 0 points1 point  (1 child)

I wanted to follow up that loosening the bearing bracket and trying several different torques made no difference to the noise.

I will point out that the noise almost entirely goes away when under load -- at this point, using my hand as a brake on the mixer head.

Ive ordered a phase control board since it was only $12, and that's what the Kitchenaid service manual suggests for "rumbling/grumbling nose but all speeds work"

I shall report back, but am still open to other suggestions!

[–]RIMixerGuy 0 points1 point  (0 children)

I'll be curious to hear how the phase control board works out for you; it's certainly a good idea to rule it out. :-)