From your description that sounds like plastic rubbing against plastic.
However if it’s the rear spoiler mounting it ought to be plastic against metal.

Might be worth spraying some silicone along edges to see if that cures it, if not might be the other parts of the spoiler as it’ll be multiple parts put together to creat the shape.

 

Very hard to describe. Really like cracking plastic sound. Sometimes that can be where the plastic is mounted into the steel body. They did try some silicone where they felt the noise was coming from. No help :-(

 

I have a similar problem on a US 2023 Limited. All TSBs related to hatch noises have been applied. As you noted, the noises fixed by those TSBs were more of a groaning or creaking sound. This is a sharp clicking sound caused by road bumps or torsion at the rear, and happens just enough to be completely annoying, and to make me very dissatisfied with a car I otherwise really like. The dealer I use for service has also been very competent in the past, but they've had the car for three months and have tried many potential fixes (re-applying the TSBs, removing the rear window to check for possible contact with poor spot welds, removing the hatch struts, removing the roof interior..., have involved technical support from Hyundai USA) and say they simply don't know how to resolve the problem ("We don't know how to fix your car"). They suggest contacting Hyundai USA Consumer Affairs and asking to be "made whole." To me, being "made whole" is replacing my car with a new one that doesn't have cracking noises, but "they don't do things like that." I'm driving it now to see if it still annoys me as much as it did three months ago.

 

Very similar to what I am experiencing but they have only removed the full plastic mold on the hatch and maybe something with the spoiler. They reapplied the TSB as well. Honestly it is now much worse since they performed these investigations and fixes. Let's say it used to be to be 20 "cracks" a mile. Now 50. It now occurs on much smaller bumps and less torsion to the body. Also used to not happen much on the highway and now I hear it more often then. Do you find that to be the case?

 

No, volume and frequency have been about the same since it started. It became a little more noticeable when the other hatch noises were eliminated. Amount of noise seems to depend on road surface primarily. On smooth highways I hardly notice it. On the bumpy surface streets in my neighborhood it happens often.

 

I have the same issue and no solution yet. They offered to take apart the rear spoiler and hatch to troubleshoot further but no guarantee it gets any better or worse. I told them to stop. 2024 Limited here.

 

We had this problem, was driving me nuts. In our case it was the rear hatch door latch rattling. Applied some gorilla tape around the latch U hook. Problem solved. Although the door is a bit sticky to open now.

The thing is scheduled for a service in April, I will tell them about it, but I don't expect those dufuses to to actually do anything about it. Its ok, got a whole roll of gorilla tape.

 

Appreciated it. I’ve done all of that including the 2 TSBs, gorilla tape, felt tape, placing a microfiber towel on the latch as well as sides of the hatch and closing, nothing works.

 

Here is my update and where I stand.

First notes: My experience with my local Hyundai dealership's service department has been excellent. They are hardworking and seem to be honest and fair. Hyundai America has been equally good to work with as they have been repsonsive and worked with me to reimburse my one month car rental that the "repairs" required.

Here we go.

I had the hatch rattle addressed twice via 2 TSBs to fix the rattling sound. That seemed to have been fixed. After the 2nd TSB, there were 2 new sounds. A soft rattle that is less obvious but always there on anything but ultra smooth road. And a cracking sound on uneven jostling type of roads or small cracks or driving over manholes for example. The cracking sound is easily heard over music or podcasts at anything but very high volume.

Hyundai America recommended that the local technician use "electronic ears" to isolate where the sound was coming from.

This was performed and the service consultant declared they had located the sound coming from moonroof assembly.

The car was in the shop for 28 days while they completely removed the moonroof and the frame and reinstalled it.

I picked up the car and drove it and the cracking was there immediately.

It does seem that the soft muffled rattle is now less obvious.

I now think they misunderstood the request to find the "cracking" sound and picked up that rattle with the "electronic ears" and tried to fix that issue.

Upon return of the car, the roof liner and pillars had many dirty finger marks. The pillars where not properly reinstalled and 3 are misaligned. Some of the fabric on the roof-liner edges appears to have lifted from the surface.

The service consultant has happily offered to address that with adjustments and a detailing to clean the dirty spots. The only issue I have with that was the car was held an extra 2 days to address these issues originally. They did clean the foot prints that were left in the back and the marks on the seats and side panels, but missed all the roof liner issues.

I just brought the car back to address these issues and have a technican ride with me to hear where the cracking sound it coming from.

The sound is getting worse and was very easy for them to hear as it happened the minute we drove out of the service bay.

The technician then proceeded to explain that this was very likely a body issue and the next step would be to have the car sent out to a body shop for repair. He also explained that another customer recently had the same issue and was told the same thing and "gave up". (Call5, was that you? . I am now feeling the same way. Between all the service visits to investigate and the actual "repairs" the car has been in the shop for at least 36+ days. It is a leased vehicle and it irks me to pay monthly for a car I am driving less and less. I have spent way too much time driving back and forth to the dealer, communicating with Hyundai America, searching and adding to forums and trying to trouble shoot this myself.

My next steps are to start the process of demanding a buy out.

I wish I could tell any of you with the same issues it was resolved. Good luck to all and hopes some of this information may inform you on what to do about your own "cracking" issues.

 

Well, I certainly have a very similar issue. Mine was in the shop 3 months, including time in the body shop, with no resolution. Hatch interior and headliner, along with rear window, were removed and then reinstalled. My dealer said they (and Hyundai) didn't know what else to do. I suppose I could pursue a buyout, but I really want an EV for my (mostly) local driving (we use my wife's Z4 for longer trips) and in thinking about replacements, I still think an I5 is the best available choice in this price range. And I'm starting to tune out the noise (and play the stereo a little louder

 

Aha! That sounds like the tick or crack sound like mine. So not really a rattle. I will see if they can reverse the changes to the bump stops and try you method. Thank you for sharing! I think I will share a video of my cracking sound to see if people recognize it as the same as theirs.

 

We bought our 2024 Ioniq 5 limited in August of last year. The rear hatch started making creaking sounds and ticking sounds. I brought it in for the first TSB hatch fix and it did stop the noises. I brought it in again and they installed a new electric latch and it didn’t stop the noises. I brought it in again for the seconds TSB hatch fix and that fixed the creaking noises but not the ticking noises. They said that they couldn’t fix that. The ticking noise was driving me crazy. I decided to remove all of the plastic trim pieces from the hatch and filled the cavities under the spoiler with Great Stuff foam. It took a couple of days to completely cure. No more ticking noises. Now our car is totally silent.

 

Here is a photo of the cavities that I filled with Great Stuff foam.

 

Duuuude! That is a radical fix but glad it worked for you. Mine is a lease and can't do that. :-(

 

Be careful using the Great Stuff foam. It is made from a derivative of Gorilla Glue. Make sure you put down plastic sheet protection on the carpeting below the areas that you fill. A lot fell out as it expanded. Once it cures you can slice away the excess in order to reinstall the trim piece. Good luck!

 

I think I would have inserted a large heavy-duty plastic bag first and then filled the bag so that the foam didn't actually bond to the internals. Or perhaps even stuffed the bag tightly with tiny polystyrene beads. In any case, I would have done one orifice at a time and checked after each application.

The effect is most likely to jam whatever is vibrating so that anything applying pressure to that area would work. That foam application is a bit of a 'no-return' solution to me.

 

The exact source of the ticking noise was impossible to pinpoint after many attempts. It comes from either a design or manufacturing defect involving flexing sheet metal. Great Stuff foam is open cell foam that can be easily chipped out if needed. Closed cell foam would be a different story. The expansion and curing of the foam is what created the rigidity in those cavities that stopped the ticking noise.

 

Simply identifying the source of the noise coming from that plastic trim area above the rear window is a big help. I may experiment with some felt tape first.

 

Australia Ioniq 5N - I had rear rattle and service centre diagnosed and replaced under warranty the plastic/rubber stops on the rear body where rear hatch closes. A residual noise remained, and they diagnosed metal separation on the chassis that needs re-bonded. Hyundai have technical bulletin on the problem.

 

There is a TSB for chassis separation? Please post it here.