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Discussion Starter · #1 ·
Had recently noticed an intermittent knocking noise when accelerating and decelerating, but as soon as I booked it in for local dealer to have a look at, it disappeared (following a rainstorm). Trip to the dealers today, it came back, and result is it needs a new gear drive unit once they can source one from Hyundai - they don't yet know how long that will take...

Technician at the dealers said it would be the second one he has had to do - just relieved he managed to notice it, although he did say that when he saw the job sheet, he suspected it would be the same issue he had previously seen.

Not ideal, but pleasantly surprised it was diagnosed, although wonder if they have already had one in, if this is a weak part or just bad luck...
 

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Had recently noticed an intermittent knocking noise when accelerating and decelerating, but as soon as I booked it in for local dealer to have a look at, it disappeared (following a rainstorm). Trip to the dealers today, it came back, and result is it needs a new gear drive unit once they can source one from Hyundai - they don't yet know how long that will take...

Technician at the dealers said it would be the second one he has had to do - just relieved he managed to notice it, although he did say that when he saw the job sheet, he suspected it would be the same issue he had previously seen.

Not ideal, but pleasantly surprised it was diagnosed, although wonder if they have already had one in, if this is a weak part or just bad luck...
What mileage is the car now?. I believe there were reports, perhaps a year or so ago of a few Konas (and apparently rather more e-Niros) exhibiting a clicking noise with a rate proportional to motor speed, audible even when running at steady speed, which seemed to be some interface issue between motor and reduction gear drive unit. Apparently modified motors were fitted and the noises disappeared...
 

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Discussion Starter · #3 ·
What mileage is the car now?. I believe there were reports, perhaps a year or so ago of a few Konas (and apparently rather more e-Niros) exhibiting a clicking noise with a rate proportional to motor speed, audible even when running at steady speed, which seemed to be some interface issue between motor and reduction gear drive unit. Apparently modified motors were fitted and the noises disappeared...
Mileage is just short of 15k. Noise is most noticeable when accelerating from a start (either slowly or quickly), and the knocking does increase in frequency as the speed increases, but also evident when decelerating with regen. I think above certain speeds the road/tyre noise masks the noise. When the noise wasn't present it was very evident how different it was...
 

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Had recently noticed an intermittent knocking noise when accelerating and decelerating, but as soon as I booked it in for local dealer to have a look at, it disappeared (following a rainstorm). Trip to the dealers today, it came back, and result is it needs a new gear drive unit once they can source one from Hyundai - they don't yet know how long that will take...

Technician at the dealers said it would be the second one he has had to do - just relieved he managed to notice it, although he did say that when he saw the job sheet, he suspected it would be the same issue he had previously seen.

Not ideal, but pleasantly surprised it was diagnosed, although wonder if they have already had one in, if this is a weak part or just bad luck...
Mine's booked in on the 28th for the same problem. Tech mentioned the reduction gear. 10k on the clock.
 

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Discussion Starter · #5 ·
Mine's booked in on the 28th for the same problem. Tech mentioned the reduction gear. 10k on the clock.
Out of interest, how long ago did they confirm the problem ? The dealer suggested to me they don't know how long it would take to get the part in, but should be ok to drive in the meantime - time for a fix less of an issue to me than ensuring the issue was identified, but interested for an idea between diagnosis and fix... They did say they expected to need the car for a couple of days.
 

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Out of interest, how long ago did they confirm the problem ? The dealer suggested to me they don't know how long it would take to get the part in, but should be ok to drive in the meantime - time for a fix less of an issue to me than ensuring the issue was identified, but interested for an idea between diagnosis and fix... They did say they expected to need the car for a couple of days.
I took it in Monday to check the modem. Without any music on when the tech drove it into the bay, he could hear the faint rattle. Not sure if they'll be able to fix it on the 28th if it needs a replacement part, but I'm getting a LEAF as a courtesy car for the few days they need it.
 

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Discussion Starter · #7 ·
Well over 3.5 months since car was taken to dealers with the "wheel of fortune" clicking noise whilst accelerating and decelerating and not yet resolved.
A month ago the reduction gear box was replaced, and even on the way back from the dealers the problem was still present. Picked up the car yesterday after 2 weeks following the second attempted fix (drive motor mounts I believe this time), and problem still present (more intermittent, but that's how it started in the first place). Have been told by dealer that they are being guided by Hyundai who are providing the part kits to replace, and there are 4 stages to attempt a fix, with the 4th being replacing the motor.... Seems that they are trying cheaper options in the hope that it resolves the issue before having to replace the motor which from what I've read seems to resolve the issue.
Of concern, the technician I spoke to said he had another Kona in at the same time with the same issue, and had seen the problem on another car when I took it in initially.
So looks like stage 3 of the attempted fix next (they have not shared what that is, and have only said they will discuss it if stage 2 didn't work)....
Loosing faith in their ability to fix problems with the car....
 

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Discussion Starter · #9 ·
Stage 3 might be pulling the motor, turning the shaft 180° and replacing it. It seems to have fixed the problem on a few examples despite sounding both arbitrary and temporary.
Cheers for the info... I assume that this will be a major job given they have already been replacing parts in an attempt to fix the problem in stage 1 and 2, although the service manager was surprised with the amount of work and parts removed to replace the gear reduction box at stage 1.... Will see what they say when it goes back in...
 
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