it's making a loud grinding noise when it's vacuuming, sounds like it's coming from the roller.

Diagnosis

The loud grinding noise in the Narwal Freo X Ultra is typically caused by high-friction interference between the main roller brush and the internal drive motor assembly. This occurs when a rigid foreign object—such as a small pebble, a plastic toy fragment, or a metal screw—becomes wedged between the brush axle and the chassis of the vacuum. Because the Freo X Ultra uses a high-torque motor to drive the brush, any obstruction creates a mechanical conflict that results in a rhythmic, metallic grinding sound as the brush rotates.

Another common cause is the accumulation of "hair rings" around the end caps of the roller. When long hair or synthetic fibers wrap tightly around the axle, they can compress into a hard, plastic-like sleeve that rubs against the interior housing. This creates a high-pitched friction noise that mimics a failing bearing. You can confirm this by pausing the vacuum during a cleaning cycle and manually rotating the brush; if you feel a "catch" or hear a click every 180 degrees of rotation, the issue is a physical obstruction in the brush chamber.

How to Fix It

Follow these precise steps to clear the mechanism and restore silent operation:

1. Power down the unit completely using the physical power switch to prevent accidental activation while your fingers are near the drive gear.
2. Flip the robot onto its back on a soft surface to avoid scratching the top LiDAR sensor.
3. Locate the brush cover plate. Press the two release clips on the sides of the brush guard and lift the cover upward to expose the main roller.
4. Grasp the roller brush and pull it straight out of the housing. Note that the Freo X Ultra uses a snap-fit system; do not pry it with a screwdriver.
5. Examine the ends of the roller. Use a pair of precision scissors or a seam ripper to cut through the hair and thread wrapped around the end caps. Ensure you remove the debris from the very edge where the brush meets the plastic axle.
6. Reach into the vacuum chamber with a flashlight. Check the drive gear (the square peg on the left side) and the bearing seat (on the right side) for any trapped grit or small pebbles. Use a can of compressed air or a vacuum hose to suck out any micro-debris.
7. Wipe the interior of the brush channel with a dry microfiber cloth to remove any buildup of fine dust that may be causing friction.
8. Reinsert the roller, ensuring the end caps click firmly into place, and snap the cover back on.

If That Didn't Work

• Inspect the Drive Belt Tension: If the grinding is internal and not coming from the brush itself, the internal drive belt may have slipped or frayed. If you see small black rubber particles inside the brush chamber, the belt is failing. This requires a full chassis teardown to replace the belt assembly.
• Check the Side Brushes: Sometimes the noise is misidentified as the main roller when it is actually a side brush that has wound up a piece of string or hair, causing the small motor to strain. Pop the side brushes out using a flat-head screwdriver and clear the axle.
• Lubricate the Bearing Seats: If the noise persists but there is no debris, the plastic bearing seats may have worn down. Apply a tiny amount of dry PTFE lubricant (do not use WD-40 or oil) to the outer edges of the roller end caps to reduce friction against the chassis.
• Replace the Roller Assembly: If the internal axle of the brush is bent or the plastic gear teeth are stripped, the brush will "jump" during rotation, causing a grinding sound. Replace the roller with a genuine Narwal replacement part to see if the noise vanishes.

Heads Up

• Avoid Wet Debris: Never use the vacuum function on damp carpets. Wet debris clings to the roller axle and hardens, which can warp the brush and lead to permanent grinding noises.
• Weekly Maintenance: To prevent axle failure, remove the roller once a week and clear the end caps. Hair buildup is the primary cause of motor strain in the Freo X Ultra.
• Debris Alert: If the robot triggers a "Main Brush Jammed" error in the app, do not force it to restart. This can strip the internal plastic gears of the drive motor, which is a non-serviceable failure.
• Sensing Clearance: Ensure the brush cover is snapped in completely. If the cover is slightly askew, the brush can rub against the plastic guard, creating a loud rattling or grinding sound.