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Nearly a year on now from my last post and reports of gear reducer noises in first-gen Konas, Niros and the Ioniq (not 5 or 6) are still flowing in, about one every 2-3 weeks, all reported on the major global English-speaking forums. Hyundai/Kia did not resolve their design mistakes and they...

10 months on and the Ioniq / Kona /Niro "wheel of fortune" noise reports are now coming in weekly, including several owners indicating that their Hyundai/Kia dealer or the importer are refusing to cover repairs out of warranty. In one case within warranty, the dealer agrees that there is a noise...

A Kona owner was quoted NZ$446 here while another paid only $130 at the same dealer. You're right, they don't know how to bill it. An owner in the US was billed for 3.5 l of oil despite it only taking one. He couldn't get them to understand that. I have a suspicion that there might be a...

Not that there's a proven relation to the tapping noise and failures, but I'm confident now that the poor implementation of the OEM particle magnet is the cause of the oil contamination. Here's a video documenting what I found. I've attached a strong magnet to the underside to attempt to...

Quite a few Kona and Niro owners have reported difficulty in convincing their dealer that there's an abnormal noise present when it first starts. Once they're past that point the TSB process is slow because it begins with a new bolts and a bracket change, then ends up with having to obtain a...

That's a long time to ignore this since the wear is cumulative. I would have killed to recognise this issue when my Kona was new after paying $75 grand of hard earned cash for it. I left it until the warranty ran out, at nearly 20,000 km. That's the image I wanted to post. Thanks. I was...

To bring this subject up to date we have (11) first-change used-oil analysis results now and the data is very scattered with many indicating high iron and aluminium levels at a low drain interval. The averages take aluminium from zero to 200 ppm and iron from 120 to 200 ppm, both over drain...

Certainly the operating temp of the gearbox housing is no higher than warm to the touch but we don’t know what happens during production. A few months ago I found a Hyundai part number for an OEM magnetic drain plug that I excitedly posted on relevant forums as being a suitable warranty...

I'll add the latest news today, a Kona owner found that the OEM internal magnet in the gear reducer is non-magnetic by poking a paperclip into the drain opening. He also photographed it to prove it's there. Perhaps, it's a cost-cutting move by Hyundai, but I'm accepting that this is the root...

I'll close this question by reporting that I've found the gearbox grounding brush on the Kona/Niro(classic)Ioniq series. It's on the tail end of the input shaft and appears to ride on the side of the bearing inner race. There is a brush on the motor output shaft as well but it's the circular...

I can see there's a grounding brush on the reducer intermediate shaft but is there also one on the motor output shaft? I'd like to hear from those who know and understand how this is done on the Leaf to protect motor and reducer bearings. Thanks!

As I mentioned above I'm leaning towards shaft eddy currents being the root cause because if the single grounding brushed ring fails to work effectively the gearbox will deteriorate without leaving debris. A gear wear problem would result in metal debris. In most countries, 96% of the global...

I would expect the intermediate shaft to be the most insulated part of the gear train during operation, due to oil films. But I'd also expect stray currents to be handled first close to the source to reduce risk to the input shaft bearings. As I mentioned the Hyundai/Kia motor has a circular...

Thanks for the interest in my post. I popped by today because there have been some developments. The latest news is that an Ioniq owner in Poland had to rebuild his gearbox due to noises and found bearing degradation. He also posted internal photos of the gearbox. As clear as day there is a...

It's the same design as the Hyundai Kona Electric gearbox. Helical-cut sideload is a minor issue on the input shaft because of the low level of torque relative to the bearing size. On the intermediate shaft it's mostly balanced between the torque going in and torque going out. The final shaft...

A couple of us Kona owners have been working over the last two months to rectify a choice by Hyundai to not provide basic ferrous particle filtration in the gear reducer, or what everyone knows as a magnetic drain plug. All the Hyundai/Kia cars I've listed in the subject line I believe use the...