Disappointed (gearbox replacements)

It definitely is not an universal issue, at least not at such low mileage. The highest known mileage Kona Electric in the UK has like 55k miles and no such issues. I probably have one of the higher mileage Kona Electic in the US with 16.5k miles so far with no issues..

 

I have 13,500 km on my 2019 Kona. No issues so far.

 

Thanks all! Great to hear. I really need a new car!


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I have just encountered this problem on my 2019 Kona at around 12K km. The whine on acceleration and deceleration was getting louder over the past couple of weeks, to the point where it was hard on the ears to drive it at highway speed.

I took it to the dealer and they put it on a lift, and ran the motor and were able to hear the sound in the shop. I had to bring it back for a full inspection today and when the tech opened up the transmission he said the fluid was completely black.

They are ordering a new transmission (I assume they mean gear box assembly) and they said it could take up to three weeks.

 

An owner on FB (in Poland, I think, a few months ago) had all this happen over a few days ending up with the gearbox failing on a highway, breaking an axle shaft and leaving oil on the road before he could get the car in the shop.
Your black oil of course is due to fine wear particles.

Well, I suppose transmission tends to be more American and gearbox more British. But from an engineering prespective, neither are confined to those with more than one ratio.

 

The antifreeze/coolant is different from ICE cars in the Kona. I wonder if the oil would be too (and it supposed to be black).

 

No, it's a common 70W GL4 and is certainly not supposed to be black.

 

Update on June 4 transmission replacement

Today I had my Kona EV back in the shop for repair of the rear brake clunk that some cars get. Earlier in June they replaced the gearbox assembly because of the whining sound. Several weeks ago I began to hear a metallic clicking sound from the left front that increased in speed as I accelerate. Thinking it was a possible return of the previous whine issue I mentioned it to the service rep. The tech took it for a drive, heard the ticking and confirmed it as a transmission noise when on the hoist. He opened up the assembly and the same black and metal colored gear oil so now they are talking about replacing the assembly yet again. The new one barely lasted 5000 km before failing. So they still have to find the problem and a fix because this must be costing Hyundai a bundle to replace transmissions every 5K or so...

 

2019 or 2020? Sorry. Read back. 2019. Got it. That's weird. I read this forum constantly and don't recall seeing this thread. * Edit 2 I'm actually on this thread but I see it's been reactivated after a while hidden away in the dozens of old threads.

 

When they ordered the transmission, how long did it actually take to arrive at the dealer?

 

I am surprised they aren't planning to replace your motor the 2nd time. After my gearbox replacement, the sound came back after only 400 kms. They then replaced the motor (new is 701), and 3000 kms later, still all good.

 

How many miles do you have on yours? Our 2019 has 25k miles and haven't had any issues yet. (crosses fingers)

 

First time in only took a week because there was one available in Vancouver. (I live in Victoria.)

 

It turns out they are replacing the motor. I got a call from the dealership today saying they are starting the process to get me a new motor. They'll call back when it has arrived and set me up with a loaner car while it's being repaired. Hopefully that fixes things for good.
Do you have any idea what the problem is with the motors they are having to replace? Bad install? Faulty components? Lousy design? Seems like a huge lapse in their testing and quality control....

 

I have not heard anything definite about the cause. But the new motor does come with new clamping bolts and I suspect it has something to do with how the new parts are mated and bolts torqued. I know when they first replaced my gearbox, the technician showed me some metal shavings where the parts mated which could be caused by fretting. I doubt though, that we, or even the dealerships will ever be told what the real cause was. In fact, they may still be just trying things to see what works.

In the meantime, mine is still good after the motor replacement, and hopefully it will stay that way.

 

So, they are replacing both gearbox and motor this time, presumably with the later version. That’s the ideal scenario as both get a fresh start.
My guess is that they leave the nose bearing out of the new motor as it’s redundant and IMHO is the cause of the problem.
But otherwise the definite cause is still unknown. Did I ask what your ambient temps are like?

 

I think you're right about the mating idea. When I got my new gearbox I noticed a slight, barely noticeable ticking sound on the driver's side that wasn't there. It seemed to almost come and go, there some days and not others. Then over time it increased in loudness to the point where it took it in. I got almost 5000K on the new gearbox before it needed the new motor. As you said, hopefully a new motor works and fixes it permanently.

Part of me thinks I should ask Hyundai if they'd buy the car back and just replace it with a new one. A new gear box and new engine in the first 12 months of ownership make me think it's something of a lemon. But without any lemon laws in Canada it would entirely up to Hyundai if they're willing to consider that.

 

But it's not a living organism; two failures does not imply more failures are imminent. In fact having a new gearbox with the best available motor will make your example now have better potential gearbox reliability than the vast majority of Kona EVs on the road.