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Discussion Starter · #1 ·
I did post about this in another thread but I'll start a fresh one as it is an actual problem with the car.

I got them to look again when getting the windscreen recalibrated and they can see there is a fault most likely with the motor. Whether internal or an alignment issue. The can't reproduce when up on the hoist only when driving around.

They said there was one case of a Kona having the same sound but no cases worldwide for an Ioniq

Heres the video again for reference but our whirring sound has gotten more pronounced than here.


He did show me the cost of a motor replacement. It would be under warranty but I'll take a deep breath and leave that for another post.
 

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Definitely something wrong.
 

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Ummmm no cases worldwide? They're wrong, I had that problem.

Motor bearing fault, dealership replaced the entire motor under warranty.
 
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Happened to my previous Ioniq at around the 40,000km mark.
 

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Discussion Starter · #5 ·
Getting the car back they said it is probably a bearing in the motor and reiterated that there is no other cases in an Ioniq only kona, there was nothing in the fault manual about it and they didn't want to replace the motor on their own say so, because it costs so much, and are messaging HMC for their say so to replace the motor which would be done under warranty.

<tin_foil_hat>Im getting half a feeling that they are stalling and would like to tell me its not that bad and to live with it. In that case they would lose a customer and the good will I put into saying what a fantastic car it is.</tin_foil_hat>

It started at about 4000kms and has now done 8000 and has progressively got worse. Nothing like showing interested people a nice new EV and its not exactly silent.

It does get me worried about the costs of out of warranty repairs because the figure they showed me was ridiculous for what is essentially a nothing part and got me thinking about how dealers are going to make money in an EV world of low cost servicing by charging exorbitant rates for repairs. This is disappointing after recently seeing a video on a repair of a Leaf having bad battery packs replaced in a job that seemed no trouble at all.
 

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Discussion Starter · #6 ·
Hyundai will replace the motor with a lead time of 6-8 weeks. Happy we get to still drive the car around in the meantime so the bearing problem must not be too terminal.
I find it awful driving our second car with no regen.
 

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Discussion Starter · #7 ·
So the new motor has arrived and booked in for the 29th. They must have to get an EV specialist to do the job and want to have it for 3 days.

Let's hope they don't have any screws left over after the replacement!
 

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Discussion Starter · #8 ·
Got the car back on the 31st with a nice shiny new motor in place. That was the only thing that was replaced apart from cooling liquid.

Driving a nice quiet EV again so the noise is definitely a bearing in the motor failing. People on a EV forum said they thought it was a bad bearing.
 

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Discussion Starter · #9 ·
So the dreaded noise is back :(

Same low whirring sound. Can we have the dumb luck of getting 2 motors with faulty bearings? Or is it something with the alignment when installed that is putting pressure on it forcing the failure.

Going back to the shop tomorrow.
 

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Discussion Starter · #10 ·
Forgot to update here.

They will replace the motor again as its the same issue and will have a team from SK oversee via a stream.

The mechanic agreed something must be putting pressure on the motor bearing, some sort of alignment into the reduction gear.

Waiting on a new motor to be delivered and said likely to be in a few weeks.

We dont really have lemon laws here on Australia but they can't be replacing a motor every 5000km. If it happens again I'm not sure what they'll do apart from replace the car. Need to look up ACCC on my rights
 

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Ugh, sorry to hear that. What a pain!
 

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Discussion Starter · #12 ·
Going in tomorrow for the next motor change out and they said they want to have it for a week.
 

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Discussion Starter · #13 ·
So an update to this. They did not change out the motor as they were not sure it would fix the issue and wanted to have the SK team analyse it a bit more.

They would get back to me on a resolution. I got some updates over the following weeks but then nothing and I would have to call.
Spin forward to the end of June and I called with my best 'This is not good enough' voice without resorting to being nasty and asked to talk to the service manager. They were very apologetic and it has finally gone in again today after a covid lockdown interruption for more assessments.

The noise is not so apparent in winter while the car is cold so we'll see what they say.
 

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Discussion Starter · #14 ·
The car was in for 4 days and don't think they did much to it. It only travelled 2km. They said they were waiting on word from Hyundai technical and after 2 weeks they called saying they would replace the motor again.

I am not confident that this would fix the problem because if it is an alignment issue with the reduction gear just replacing one half is not going to solve the problem. A wait for the part to come which they cant give an eta.
 

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What a nightmare!!!!
 

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Discussion Starter · #16 ·
The car finally went into the shop on Thursday for the second motor replacement.

Really not enarmoured with JH, they called saying the parts been here for a couple of weeks didn't anyone call you. Great fine just book it in. I take it in early on Thursaday and they say it got the managers name on my file well get it done pronto but will take a couple of days at least.

Thanks to autolink stalkerware I can see it moved from out the front at 3pm on Thursday afternoon to the back lot and there it has stayed. So much for getting on with the job.

Will be calling the manager on Monday morning.
 

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Discussion Starter · #17 ·
The saga continues!

By dumb luck our courtesy car pick up a screw in the tire so I took it in to get fixed on Monday morning and enquire whats happening. Sorry My Castle theres only one person who can do the job and he's flat out, might be done by the end of the week but no promises. Sigh.

Called Friday afternoon to find out as I can see some back and forth testing done on Thursday and Friday, they must be doing something. Motor has been replaced but the noise is still there and they are waiting on Technical for advice. More sigh.

So my guess is the bearing in the reduction gear went as well on the original motor failure but took its time failing audibly. Im betting there is another 6-8 week wait for a gear box to arrive and there would be no point giving it back to me to drive given the possibility of the new motor failing as well because obviously there is an alignment issue in the mating of the motor and gearbox causing the issues with the gearbox being the culprit. Second motor they took out is probably alright hahaha!.

Not one to get annoyed and scream and shout my displeasure but its a bit ridiculous. 8 months is not good enough to fix the issue.
 

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Discussion Starter · #18 ·
Had a call with Hyundai Australia after calling the dealer again with no updates for a month who said they could do nothing as its between the dealer and Hyundai Technical. He called the dealer who told him they were waiting on a response from Hyundai Technical as to whether the noise was normal or not. The service agent would not even take a complaint about the level of service I am receiving and the length of time its taken to not resolve the issue because the dealer is waiting on more information.

What irked me about the call is that the agent said they see a motor replacement was authorised 15 days ago and JH told him the motor was only just replaced when in fact the motor was put in on or about the 21st of September with me dropping of the car on the 9th and picking it up on the 24th.

Am drafting a letter to the dealer outlining my rights under Australian Consumer Law consumer guarantee but giving them one last chance to effect a repair.
Consumer guarantees require vehicles sold to:

  1. Be of acceptable quality;
  2. Be fit for the purpose for which they were acquired;
  3. Correspond to any description attached to the goods prior to the sale; and
  4. Correspond to any sample of the goods that was offered to the consumer prior to the sale.
If a vehicle is unsafe or substantially unfit for the purpose for which it was bought, and incapable of being easily remedied within a reasonable time, you may be entitled to a replacement vehicle or refund.
Pretty sure a reasonable time has passed and I would probably go for a refund as I don't think Hyundai Australias service support is not up to scratch as much as I love our little red car who has served us well over 27000kms despite the motor problem.
 

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Discussion Starter · #19 ·
Lol this is still going on. 2 months afterwards the dealer has said they have a kona TSB to follow for the replacement but don't have one to follow. I did find an eNiro TSB from Apr 2021 that details troubleshooting a drive train noise from both the motor and the reduction gear. The kona environment and ioniq have very similar drivetrains.

I did manage to get the car up on a hoist to check the reduction gear oil and it is good so it not a chewing gears issue . Bonus shot of what the underside looks like

Tire Automotive tire Motor vehicle Wheel Urban design

Vehicle registration plate Automotive parking light Vehicle Tire Car

White Automotive tire Line Composite material Gas
 

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Lol this is still going on. 2 months afterwards the dealer has said they have a kona TSB to follow for the replacement but don't have one to follow. I did find an eNiro TSB from Apr 2021 that details troubleshooting a drive train noise from both the motor and the reduction gear. The kona environment and ioniq have very similar drivetrains.

I did manage to get the car up on a hoist to check the reduction gear oil and it is good so it not a chewing gears issue . Bonus shot of what the underside looks like

View attachment 37404
Nice, it looks like the AC compressor is bolted up to the motor and gearbox assembly, taking advantage of the same anti-vibration mounts to save weight. Clever chaps at Hyundai, sometimes...
 
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