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Roomba keeps giving error 2 even when brushes are clean

have a 5xx ROOMBA keeps getting error 2 CLEAR BRUSHES. Brushes are clean and unie will work for maybe 10 - 15 minutes then get same message. when checking brushes they are clean. This keeps repeating.

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I’m having this problem right now! And I can’t get them brushes in to where the top piece closes over them properly either. We worked on it at least an hour!

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I bought a new brush cage for a 627!series as recommended on the iRobot site.. did a factory reset and still no luck I can get 1 to 2 mins before the error2 kicks in..

Driving me crazy..

Starting to look at different brands now..

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Everyone should start looking for different brands. They are junk.

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HIC. I have the same problem with my Roomba S9+. I have cleaned all brush but motor keep stuck. I have to turn the brushes with hand before tap clean button. How can i fix this, pls help!

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I agree with Frank have an S9 that does the same thing I will never buy from this company again

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Late to the game but if it helps anyone else in the future, I just dealt with this even after I made sure the brushes were clean. I have long hair and a dog so I knew there had to be little some pocket of hair in there that I couldn’t find.


What fixed it:

I took the whole thing apart to give a good cleaning but two things made a WORLD of difference

1. While disassembled, I popped the front wheel assembly off and then took the front wheel out of the assembly. The metal posts that hold that ball in the assembly where completely twisted with hair (like a spool of thread). I was able to slip the hair right off and then pop the wheel back in the assembly

2. This one was HUGE: On my particular model, when you remove the brushes to clean them, there’s the square end and then there’s the other end with the two plastic prongs (mine is green and yellow). On a whim, I pulled off the yellow prong part (the side opposite of the square end) and BAM: dense spool of hair. I have no idea how it got into that tiny little space but removing it from both brush assemblies completely fixed it for me. Good luck!

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Andrea, your #2 suggestion was the issue and fix for me. Thank you! - Den

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Great, suggestion No. 2 fixed my problem as well!!!

Thanks a lot!!!

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I had the same error 2 problem of tangling. Bought set of new OEM iRobot rollers. Fully cleaned, I mean I disassembled the 880 model. No blockage of anything. I even looked inside the gearbox case that drives the rotating rubber brushes. Sparkling clean and plenty of the original grease. Not a trace of any hair or dirt. Turned it loose with with the new brushes after the cleaning. Same error code of tangling after 10 minute run time. I contacted customer service and they recommended a new brush roller assembly. I bought and installed it easily. Started the 880......10 minutes later, same error code of tangling. This machine is as clean as brand new. So, I figured it must be the battery pack is worn out after 4 years of use and does not produce enough amps to turn the rollers when on carpet. Awaiting the battery pack. This is my last attempt at fixing the 880. If this does not fix it, I’m moving on to a different brand. I will post a result after the new battery.

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I was wondering about the battery too. I'm on my second battery. Have new brushes, wheels, cleaned the sensors and obviously (since my hobbies are dogs and sewing) cleaned out every thread, hair and fluff with tweezers. Mine is also 880 and I'll watch for your post. Thanks

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Number #2 did it for me as well

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Have you tried to check the rollers carefully right after getting the error 2? For some reason Roomba is thinking that something is stuck in the robot vacuum rollers as they creating the resistance. If you have it for a while it might be that the inside gears are getting resistance from dirt. You can see in this video how to repair it.

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I have done everything and it is still coming up with the error. I cannot work it out. Gears are clean, lubicated, I have completely cleaned it, replaced brushes but cannot find the issue.

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Thanks for the tip. The yellow "double prong" ends popped off from each roller (just push from the behind the rubber extractor) and revealed a lot of bundled hair that was blocking the turning of the axel. I used an exacto blade to scrape away all the hair down to metal (plastic?) and this solved the problem. Saved me the cost of replacement rollers, or a new Roomba.

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Thank you very much. I had both issues. Did number 1 and thought that was it. Nope. So I did number 2 on my roomba 5e rollers and wow I could not believe the hair and other stuff wrapped around the inside of the roller. O am certain this was the problem...unseen hair and yarns.

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OMG, I just tried the process to clean those green brush ends - took off that white plastic end thing and you wouldn't believe all the hair and gunk that was caught up in the thing - both of them - I've had this I3 roomba only 3 months and was about ready to return it and demand my money back but this very well kept secret seems to be the answer to the 'clean brushes' issue. I wish I could figure out hot to post a pic of the gunk that was pulled off those two roller ends !

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With my e5 model I had cleaned everything but I kept getting the error that the main brushes were stuck. I took the rollers out and popped the hexagon end off by just slightly folding down the plastic, grabbing it with pliers. It was completely wrapped with hair inside the actual brush roller.

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Yes it worked for me too, i have a i7 model

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I had same issue where Roomba kept telling me to clean Rollers , fairly new Roomba, this fixed it. You can tell when you take the rollers out and holding large square end it should spin easily when turning small square end. huge difference after cleaning.

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This worked for me after trying many different things.

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This did the trick for me as well. Thanks for posting

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Something is impeding the drive train. Usually, it is the brush loaded with stuff it picked up. If the brush is clean, it obviously is not a clogged brush. The next step requires you to disassemble Roomba. Take brush, roller, and brush keeper. Easy part. Remove the bottom plate. It is held on with screws. Don’t lose them. You also mustunscrew and remove the circular sweeper thing. The bottom should come off. Now you must remove the entire piece that holds the brushes. Careful because the motor wires are attached. There is enough slack that you need not - and should not- unwire the motor. The piece that holds the brushes comes out. But not easily. There is a spring plastic catch right and left. You must depress both simultaneously (takes two hands), grip the brush holder piece (third hand) and hold the body of roomba attune rear (fourth hand), and pull the assembly out (fifth hand). People with five hands find this easy. It is almost impossible with only two hands. The entire green thing comes out. Including the gear box on one side. Carefully disassemble the gear box. Five or six tiny screws to keep track of. Lift off the cover from the gear box. There are several Teflon gears. They just slide off. Remember which one came from where. Likely, each gear will have accumulated sludge, and the axles will have strangled themselves I loose threads. Clear everything.. put the gears black in. DO NOT CLOSE UP YET! Spray everything in the gear box with WD40! Very important Now close the gear box and reassemble everything. The two front spring clips on the front of the brush housing will fight you. There should no longer be error 2. The brushes weren’t clogged. The gears were gummed up. Stuff migrates into the gear box over time. You have to execute this goat rope every year or two. There is not much to the Roomb@. All that’s left is the battery, which is easy to replace, and the motor, which is easier to deal with than the gear box was. Most of the functionality is in the electronics.

Almost none of these instructions come with Roomba or are in the manufacturer’s website. Phone help is clueless. You do not need to trash the Roomba or pay for repairs. Good luck. Remember that persistent Error two does not mean that the brushes need attention. It means that the drive train is clogged!

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3 Comments:

Thank you!! WD40 was the key for me. I cleaned everything and put it back together before reading this. It still didn't run long without Error 2. I opened everything up again and used WD40 and then it ran fine. I still get a brush error sometimes because I have thick long hair, but that's just about regular brush cleaning.

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Thank you, gears were so bad! Soaking, toothpick cog cleaning, lubricant, she's purring like a kitten. I was able to take out the housing with two hands and two knees.

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WD40 is a penetrating oil, not a lubricating oil. Are we sure about using that on the gears?

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We had same problem. Make sure the little”string” between the pully on end of motor and middle of blue chassis. If it missing that’s the problem. Roomba website shows where it is We used a piece of nylon thread/ thin fishing line She’s working great.

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Problem fixed. On the end of the brush that has the plastic and role bearing spray lubricant spray on it. This will allow it to move freely inside the brush. Of course I didn't figure this ut until disassemble of the roomba and checking the drive gears.

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I shot some wd 40 in where the rollers go ,the end where the gears are,and it took right off and finished the floor,this is after I got many “clean the brushes “,but the brushes were clean so it just needed a little lubing up

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Argh this is an annoying error. I kept facing it as well. It’s super important to check the rollers - that is the first thing I would suggest to do. Usually, that is the problem. The rollers are probably just stuck or dirty. Otherwise, google troubleshooting for roomba. There are many guides available. I saw this one. That’s what I did.


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I have completely disassembled mt Roomba 500. Cleaned brushes meticulously, disassembled the drive train. Cleaned gears and axles. Still get Error 2! I infer that the resistance is upstream of brushes and gears. Perhaps the motor shaft itself. That will be a very tough repair for me

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Pull out the brushes and pull off the yellow part and clean out the yellow under side and around the spindle on both brushes. Fixed my issue.

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So I received this error. I removed and cleaned the rollers as well as the entire cage, this did not fix the issue. I replaced the rollers with new ones as the existing ones were not in the greatest of condition. Replacing the rollers did fix the issue.

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Interesting. I bought a whole new kit. Brushes, side brushes and filters. I cleaned everything very well before replacing all the above. Now, it starts saying there is a #2 error to check the brushes. They are sparkling new. So I decided to clean up the old rollers.. now it is working fine. I don’t get this at all. She doesn’t want the new rollers.

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The #2 error continually comes up after 5-10 minutes. Especially on the carpet. On the linoleum, she works well.

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@Lori Ann Laybourne, I have exactly the same problem! I bought the whole replenishment kit. And now error#2 comes up after a few minutes. When I change it back to the old rollers, no error! I'm wondering, is it the carpet? But why would the old ones work & not the new ones? I also noticed this blue sun-like light flashing. Never seen it before.

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Cleaning the front wheel fixed the issue for me.

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Does the front wheel spin freely?

If not, clean the front wheel

This fixed the problem for me :)

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I posted this a while back. The brushes are not the problem. The gears that drive the brushes are the problem. The gear train is inside a green housing on the left side facing Roomba front. Removing it is a pain, but it requires no special tools or skill. Removing the brush holder is a trial, but it is just spring loaded right and left. The problem is that you must depress the right clip with your right and the left clip with your left hand while pulling out the housing with your middle hand. At least three hands required. Then extract screws and pull off the side of the housing. Gears slip on and off easily. You will find an amazing amount of gunk, threads wound around axles, etc. You get Error 2 whenever the motor experiences excessive resistance somewhere in the drive train, not just the brushes! Before you put the gear cover back on, spray the inside with WD40. That should fix things for a long time. But eventually it will happen again.

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The main brushes are made of rubber and were rubbing against the left side of the compartment where they sit in on my unit. I took them out and pushed the inside of gear-like plastic hexagon bolt left and right until I correctly adjusted them to the center and that appeared to fix the problem. Remember anything that creates resistance on the brushes will trigger this code.

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My e5 Roomba was a little over a month ‘old’ when it started to leave clumps of hair around rather than pick it up. We have 2 German Shedders and 5 cats - and despite having to stop the machine to empty it every 15 minutes, it has still made an incredible improvement in reducing the hair and dirt on the floor. I figured it was time for a ‘deep clean’ - and indeed it was. I removed the rubber brushes and cleaned them with water, cleaned the dirt bin using water, changed the filter, removed and cleaned the front roller. When I was done (and everything dry), I set the Roomba to start. It ran for about an hour, and then got caught in a cord under a buffet. I pulled out the cord, and the pressed start. In two minutes it stopped with an Error 2 clear the brushes. There was nothing there, started it again, and in two minutes another ‘Error 2’.


I went through all the many good suggestions on this page - including removing the end bearings and removing the amazing amount of twisted hair underneath. I tried to be sure the rubber brushes were centered. Nothing seemed to work - I continued to get repeated ‘Clear the brushes’ messages after two minutes. I finally resorted to what I really didn’t think would work: I ordered the ‘replacement part kit’ with new brushes, sweeper brush, and filters.


I replaced the brushes and the sweeper brush. The Roomba now works again. It seems strange that the brushes would be bad after only 1 month. Perhaps that cord catch damaged them. Regardless - the new brushes fixed this problem for me.

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My Roomba i3+ was doing this exact same thing. I purchased it for Christmas, and the next day it started the "Clear the Brushes, Error Code 2" message. The Roomba tech support folks are sending new brushes, so I hope that works.

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I had the same issue

Some times I heard that my roomba tried to brush.. Just for a short moment just to give up..

I had to pull of the brush cage and re solder a wire that was loose on little engine (that's beneath the brush cage when the roomba is up side down) that seams to lift/lower the brushes (I'm not sure about that)..

Now it works like a charm

Easy like a plätt

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I have a Roomba 800 series, and has the rubberized roller “brushes”. Error 2 announced over and over, and a blue light on top of Roomba with a brush insignia. I took the entire machine down to parts, disassembled the roller gear box to see if it was clean. It was spotless and still had plenty of the original factory grease in the casing. The rollers seemed, but removed them and thoroughly clean them. Every piece and part of the machine was gleaming and clean. Reassembled. Turned Roomba 800 loose, error 2 clean brushes within 5 minutes. So, bought official iRobot replacement brushes. No joy. Same error 2 announced and continual blue brush warning light when Roomba is on my rather thin carpet. No clue why this problem recently developed and cannot be rectified.

Stumped in Atlanta.

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@starlifter777, I have the same problem but it only came up when I replaced the rollers with genuine iRobot Roomba ones coz I haven't replaced them for 4 years now and I was thinking maybe it would clean better with new ones. So I decided to put back the old rollers. And it works fine. But I feel bad for wasting money on the new ones that I cannot use due to the error.

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I was having very similar error reporting under the same conditions you have described. I went through a very thourough and deep cleaning process, full disassembly and a bit of dirt and dust, but nothing catastrophic enough to cause the roomba to continually shut down for reasons of error 2. I followed iRobot tech rep advice and bought new roller brush gear assembly. I put in the brand new unit assembly( very easy to do) and turned Roomba loose. Same error code and Roomba would shut down. So, I decided to replace the 4 year old battery. Popped in the new battery and fully charged up the new battery pack for about 7 hours. I let loose Roomba with new fresh fully charged battery pack and the error 2 of tangled brushes was no more. The unit ran for over 2 hours non stop and docked up to recharge. The old battery was the problem.

Update (11/09/2022)

I have an 800 series and I had the same problem for quite awhile. I took mine apart down to the gear classes in the motor drive, and could find nothing wrong. I replaced several parts on recommendations from Roomba. Nothing fixed the problem. What finally “ fixed “ it for me was replacing the battery. I bought a non OEM battery, it’s more powerful and lighter weight than the original. Runs for a good 2-3 hours nonstop, no more error messages. This could be the fix you are looking for. I bought the battery on Amazon for a very decent price. My 2¢.

Hope it works for you if you try this method. If doesn’t fix your error problem, return your battery for refund.

Regards,

K

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This is an update to my earlier post. I had continual error code 2 of tangled brushes that stopped my 880 series every 10 minutes. But they are EXTREMELY clean. But I replaced them OEM brushes, an entirely new brush roller assembly from iRobot at their suggestion. I installed and thoroughly cleaned the machine. Started Roomba up…….same error code. So I bought a new battery pack, a Lithium Ion, non Roomba manufacturer, but had good ratings. SUCCESS!! The new battery solved the error code 2 tangled brushes and I probably wasted money on new rollers and roller brush assembly as well as wasting a significant amount of time doing extensive disassembly that required only a new battery pack. The lithium battery is much lighter which allows the Roomba to climb on board atop thicker rugs much easier and it runs for a at least 2 + hours before heading back to base for recharge, even though battery indicator is still green. I recommend make sure brushes are clean and the front wheel spinner is free to swivel. Then buy a new battery that fits your series of machine. Charge the battery fully. Do a reset of your Roomba. Then turn it loose for tangle 2 error free cleaning once again! The disassembly and extensive cleaning as well as new new parts did not solve anything. Only the NEW Battery fixed it for me.

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@starlifter777 - have the same issue with my 980. Ready to try the battery. Are you willing to share which one you got and if it is still working ok at this point in time?

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I bought the SPARKOLE 5300mAh Extended Life Lithium battery on Amazon. It fixed all problems I was having for months! It’s still available for $40.00. It continues to work very well and runs Roomba for at least 3 hours nonstop between charging cycles. I have to stop it, clean the onboard bin, reinsert the collector bin and send it on its way for another round or two, all on one charge. Excellent battery!

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There's good advice for maintaining a Roomba, tried some of them myself to little avail. Ultimately opened up gearbox removed the gears cleaned meticulously and reapplied lithium grease. I noted there are two small steel-bushings 2 of the gears fit inside. They're inside the gear compartment and they do pull out. One of them still spun freely, the other seized up. Cleaned out all the crud and soaked in WD-40 and applied lithium grease. For now it seems to be working fine, but instead of just ordering new rollers or brushes, check out those little steel bearings if replacing the brushes and rollers doesn't work

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You must pull off the ends, yellow , that fit into the cut outs, Opposite the drive ends. They fill up with hair and lock the brass bushings under the yellow cap. I have disassembled many Roombas, Sharks, they are all pretty much the same. Hair and string are not their friends. I have two Roombas over five years old, no issues other than batteries and Hair. 9, 2 dogs, 7 cats can keep them busy. I have two cats that start them when they are bored!

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Did that no use,

Even bought new brush cage and brushes but again error kicks in after a minute of use..

Reply from rumba was to send in to be repaired..

So not worth the costs guess it’s heading to be recycled:(

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Roomba would run for 2 mins and then the error. I think the problem was when I took apart my roomba to replace the gears, I didn’t put the motor that turns the gears back in properly.

I took my roomba apart again, I ensured the motor was properly seated in its grooves, and the cable that goes in the wheel, was not loose but in its groove and seemingly tight.
Then it worked fine after that.

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I had the same clean brushes error. Disassembled the unit completely and cleaned every rotating part. After reassembly, I got the same error message, however, I noticed the brushes weren’t turning at all. It didn’t make that same grinding sort of noise. Ran really quiet till it shut down.
Dissembled the unit again and removed the roller brush module. Removed the motor and jumped it using the recharging base. The motor ran. Reassembled and ran the unit. No error message. So far, so good.

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Edit:

Same thing continued to happen. Occasionally I could get it to run again by spinning the rollers manually. It’s a pain having to jump start the unit almost every time it runs. I finally purchased a roller cage on EBay for $20. After installation the unit runs like new. Thinking the roller drive motor was faulty.

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I cleaned every inch of the brushes and gear case. I purchased a new brush housing and it works well now. I’m thinking the motor that drives the gear case was faulty.

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HI Ben,

The fault with the Roomba is a hardware fault and i recommend for you to contact the manufacturer as they could have a recall on your product or even offer replacement

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I was having the same issue. Cleaned the brushes, put everything back and got the error again. I finally took the brushes off and removed the grey ends and found a ton of dog hair under the grey brush end. Once removed it worked fine again with no error code.

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These type of errors require much further mechanical in depth disassembly, inspection, replacement of parts, and hopefully the found problem will become apparent and fixed. I did a complete tear down and found very little wrong with any mechanisms. The errors continued. Ultimately, the elimination of errors ceased upon replacement of the original OEM batteries with a new, lighter, more powerful lithium battery pack. Amazon has multiple choices of non OEM battery packs available. Read all of the reviews as they are very helpful and make sure you pick proper size to fit your model of Roomba. A higher amp hour lithium battery is very helpful and a slightly higher voltage than your original battery pack will return your Roomba to a much better operating machine. It will run faster and much much longer between charges.

Hope this helps any of you that have the continual errors of brush errors that continually halt your Roomba in its tracks.

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Try replacing your old battery pack with a new lithium battery pack. A higher amp hour rating ands higher voltage will breathe in new life to your tired Roomba. Amazon offers quite a few choices so make sure you select a properly sized battery pack to fit your Roomba. And read the reviews concerning the various battery packs you are looking at. I did NOT buy a Roomba OEM battery and my machine now works faster, longer, and lasts much longer between charges.

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Check this short video: you need to take off the yellow ends from the grey rollers and remove hair https://youtu.be/NdDhl7v0-9Q

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Me too! Worked well.

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We just had the same Problem with the Roomba S9 from Costco after only owning it 4months. We had the "Clean Brushes" error pop up about 6-7 times in a row and it was very frustrating. The first time it errored out, there was actually hair to clean out, but the other 6 or so times, there was nothing.. I believe the problem comes from when you clean the two green roller brushes and put them back into place that they are not aligned right. (Maybe a design flaw?) After the last time that it happened, I just turned the robot over and turned the front roller about an 1/8" to 1/4" and it has not errored since.

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This exact behaviour happened to me. I clean out the rolls and those yellow end pieces. No change. I then pulled out cleaned out that plastic piece that is attached to roll and yellow end. The foam inside popped out. Removed all the hair meticulously.

Runs perfect.

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Tried everything, including cleaning the front roller ball. Nothing worked.
However, I have two Roombas (different models), one upstairs on carpet and one downstairs on wood floors. I swapped them. The one that used to get the error works perfectly on the wood floors. The other one is doing a great job on the carpet. So there was something about the thick pile that for some reason started giving my other Roomba fits. Go figure.

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What actually fixed it for me was changing brushes. I'd bought some from Amazon which were off-brand, and that was the one which kept giving the error. When I put the old, Roomba brand brush back in, the errors stopped.

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Super late to this. But maybe it will help some in the future. My roomba was doing the same thing. Even with brand new brushes. I completely disassembled cleaned/greased gears, replaced wheels cleaned front wheel. The whole 9. Still the same thing. Tried factory resetting, nothing.

One thing I noticed was it would run just fine on the hardwoods. But as soon as it hit the carpet it would “hiccup” (as my two year old calls it) before throwing the dreaded error 2 code.

So I tried a theory. The bristles on the brush were too long and jamming it up. So I pulled out the scissors and slowly and in very small amounts trimmed them shorter. I mean like a cm or two. Not much at all.

Works just fine now. Might be worth a shot for some.

Update (07/13/2022)

Super late to this. But maybe it will help some in the future. My roomba was doing the same thing. Even with brand new brushes. I completely disassembled cleaned/greased gears, replaced wheels cleaned front wheel. The whole 9. Still the same thing. Tried factory resetting, nothing.

One thing I noticed was it would run just fine on the hardwoods. But as soon as it hit the carpet it would “hiccup” (as my two year old calls it).

So I tried a theory. The bristles on the brush were too long and jamming it up. So I pulled out the scissors and slowly and in very small amounts trimmed them shorter. I mean like a cm or two. Not much at all.

Works just fine now. Might be worth a shot for some.

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I only needed to replace the broken brush, but I bought a new set of brush, wheels, and filter that is cheaper than the brush alone. So, I replaced them all, NEW brush, wheels, and filter. Then, I kept getting Error 2 after every 30 seconds. It was so annoying. I noticed the Roomba ran slightly higher than before. It was about 1/4 higher than the carpet, now it is about 3/8 higher. I installed the old wheels back and SOLVED the problem. It is working on sensing the height. The new wheels pushes the Roomba up and it thought there were debris there. No more Error 2!!!

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there is a little tether on the motor under the assembly, it looks like a tiny metal wire with a brass head, Once i removed that the brushes started working fine.

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I was having this issue with no hair clogging the brushes and this is what i did to fix it.

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I have been suffered with error2 from my roomba S9 for over a year, and today, the problem solved - I changed the entire cage of the main brushes! (Of course I deep cleaned everything, sparyed WD40, as well) The connection between the drive train and the main brush motor in the cage was bad, which made the robot thinks the main brushes falling behind. The connection of the new cage seems improved - The photo I attached is the older cage, and the marked part is the one improved in the newer cage - They are covered with the black rubber. Hope this helps somebody!

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