Clunking Vibration type sound

[Rick2020Kona]

@Jamas I put it in the engine bay, it was held against one of the sides by a cable that was already there.



Is that 4 days including getting the part in, or it took them 4 days to swap the motor over. 4 days seems like a really long time to swap an electric motor over.

Dropped off on a Monday 1330 hr.
Motor ordered & shipped air freight. Picked up car Thursday morning.
I actually thought that was very reasonable


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[wizziwig]

Looks like they are getting much better at handling this in a timely manner compared to those of us who waited 6-12 weeks last year due to lack of replacement motors. Hopefully this Canadian service experience will be similar in other parts of the world. They also kept the original gearbox in my eNiro and only installed the new motor revision.

Do you notice any difference in noise of the replacement motor compared to your stock motor when car was new? I could swear that my original motor was much noisier even when the car was new and before the tapping noises started. May have been defective right from the factory and deteriorated further during use. Or maybe this new motor revision is just quieter in general. Wish I made some recordings when I first received the car.

 

[electriceddy]

Just got a call from my local dealer (Langley) and they just got in the parts for my motor replacement (confirmed as the 701). Scheduled it to be done next Tues. So will see. Interestingly, haven't heard the tick tick recently, even though it has been cool here lately.

Let us know how it turns out, some copy of the showing the parts including the new bolts if applicable would be nice

 

[R P]

Let us know how it turns out, some copy of the showing the parts including the new bolts if applicable would be nice

I'll see what I can do. Last time they showed me the old gearbox and the metal shavings, so will see what things look like this time.

 

[Rick2020Kona]

Looks like they are getting much better at handling this in a timely manner compared to those of us who waited 6-12 weeks last year due to lack of replacement motors. Hopefully this Canadian service experience will be similar in other parts of the world. They also kept the original gearbox in my eNiro and only installed the new motor revision.

Do you notice any difference in noise of the replacement motor compared to your stock motor when car was new? I could swear that my original motor was much noisier even when the car was new and before the tapping noises started. May have been defective right from the factory and deteriorated further during use. Or maybe this new motor revision is just quieter in general. Wish I made some recordings when I first received the car.

I will provide an update on this motor replacement in a couple 1000K.
Fingers crossed everything works out OK and i also, still have 90 months of warranty left.


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[R P]

Got my car back yesterday with the new traction motor, E701, installed along with the new bolt-flange kit. No noise now, but haven't had a chance to drive it much yet. Last time after the reduction drive replacement, clicking noise came back after only 400 kms. Can only hope for the best...

 

[electriceddy]

Got my car back yesterday with the new traction motor, E701, installed along with the new bolt-flange kit. No noise now, but haven't had a chance to drive it much yet. Last time after the reduction drive replacement, clicking noise came back after only 400 kms. Can only hope for the best...

That's really good to hear everything worked out, sounds like a good dealership to be associated with.

 

[R P]

That's really good to hear everything worked out, sounds like a good dealership to be associated with.

Well, they wouldn't listen to me the last time I had it in, when I suggested that maybe the traction motor needs to be replaced instead of the reduction drive. They wouldn't even call Hyundai Canada. This time, they did. However, I refrained from telling them I told you so... Probably not a good idea to piss off the guys who are going to do major maintenance on your car.

 

[R P]

I just noticed another thing now that am driving it again after the motor replacement. There used to be a barely audible low rumble sound when driving at low speeds. I think this may have been drowned out at higher speeds by road and wind noise. Anyway, I didn't think that was abnormal, because it was always there, even when the clicking sound wasn't. Now that rumbling sound is gone, too, and at low speeds only thing to be heard is the vess and nothing until higher speeds with the wind and road noise.

 

[apu]

Well, they wouldn't listen to me the last time I had it in, when I suggested that maybe the traction motor needs to be replaced instead of the reduction drive. They wouldn't even call Hyundai Canada. This time, they did. However, I refrained from telling them I told you so... Probably not a good idea to piss off the guys who are going to do major maintenance on your car.

Its similar to my experience when I in a very non confrontational manner suggested to my dealer's EV technician that first remedy might be to rotate the driveshaft 180 degrees. I even provided him documentation that eluded to this. With what appeared to be a dismissive mannerism he was quick to state that this can't be done. Okee dokee, after protracted communication with HYTAC , guess what he is doing next week.

 

[R P]

Its similar to my experience when I in a very non confrontational manner suggested to my dealer's EV technician that first remedy might be to rotate the driveshaft 180 degrees. I even provided him documentation that eluded to this. With what appeared to be a dismissive mannerism he was quick to state that this can't be done. Okee dokee, after protracted communication with HYTAC , guess what he is doing next week.

Actually, when I look at my invoice I got back after the motor replacement, they list having rotated the spline 180 degrees and retesting, but the sound came back. The service advisor didn't mention that when I picked up the car, just that they replaced the motor and did the software updates.

Makes me wonder if they actually did that, since they already had brought in the new motor, but needed to say it to satisfy HYTAC.

 

[wizziwig]

I just noticed another thing now that am driving it again after the motor replacement. There used to be a barely audible low rumble sound when driving at low speeds. I think this may have been drowned out at higher speeds by road and wind noise. Anyway, I didn't think that was abnormal, because it was always there, even when the clicking sound wasn't. Now that rumbling sound is gone, too, and at low speeds only thing to be heard is the vess and nothing until higher speeds with the wind and road noise.

I found the same on my Niro. The replacement motor sounds quieter than the original motor even before it developed the clicking. I bet there are many border-line defective motors out there with owners not even realizing their noise levels are higher than they should be.

 

[Electric Rich]

I just noticed another thing now that am driving it again after the motor replacement. There used to be a barely audible low rumble sound when driving at low speeds. I think this may have been drowned out at higher speeds by road and wind noise. Anyway, I didn't think that was abnormal, because it was always there, even when the clicking sound wasn't. Now that rumbling sound is gone, too, and at low speeds only thing to be heard is the vess and nothing until higher speeds with the wind and road noise.

Hi RP, very glad you have written the above, I too can hear a very low rumble/hum that comes and goes but shouldn't be there. Too quiet a noise to get the dealer to hear, I know what they would say. "what noise'.

 

[Jamas]

I do believe the "clicking/tapping" noise we hear at low speed (below 10 mph) turns into the higher pitch "rumble" sound at higher speeds. The best analogy for those of you that have done this as a kid is a baseball card in the spokes of your bicycle. Low speeds and you hear "tic-tic-tic". At higher speeds, you hear "errrrrr...".

As stated, the hard part is getting the dealer to hear it as it is not very loud. Even harder in the summer as you need to drive with the windows closed and climate control off to minimize any sounds that might mask it.

 

[R P]

I do believe the "clicking/tapping" noise we hear at low speed (below 10 mph) turns into the higher pitch "rumble" sound at higher speeds. The best analogy for those of you that have done this as a kid is a baseball card in the spokes of your bicycle. Low speeds and you hear "tic-tic-tic". At higher speeds, you hear "errrrrr...".

As stated, the hard part is getting the dealer to hear it as it is not very loud. Even harder in the summer as you need to drive with the windows closed and climate control off to minimize any sounds that might mask it.

I am not sure about that. In my case, the tick tick was very distinct at low speeds and disappeared at higher speeds. It was also very temperature dependant, at least in the initial stages. The low rumble sound was always there (although faint), and was most audible at low speeds. I think the road noise drowned it out at higher speeds. I am not sure exactly when the rumble sound started, as I only noticed it when it was gone after the E701 traction motor replacement. Previously, I thought it was just normal.

There are other sounds that others have mentioned before incl loud high pitched whines. I never experienced those. It could be that this traction motor could have had different defects that didn't manifest with everyone.

I think the rumble sound will be hard for the dealer to acknowledge, as they have nothing else to compare to. But very hard to ignore the tick ticking. I would still encourage owners to ask the dealer to check with Hyundai Canada or US about the rumble sound, to see if they can help diagnose it.

It is also interesting that some with high mileage never experience any of these problems. BlueKona has more than double my miles, but no issues. Maybe it is due to his car never experiencing winter?

 

[apu]

Got my car back after the motor shaft rotation today, service advisor claimed it was fixed so I took it home. On the drive home it actually seemed worse, its now audible at higher ambient temps (29C) and has an associated intermittent high frequency resonance over 60 km/hr. It actually sounded like an exhaust note of an ICE vehicle. I made a video recording in the motor bay, its clearly not right. I drove back to discuss with the service advisor. He heard the recording, has to talk to the tech next week and I guess we will see what happens next. I have to admit its getting kinda annoying and big waste of my time.

 

[electriceddy]

Got my car back after the motor shaft rotation today, service advisor claimed it was fixed so I took it home. On the drive home it actually seemed worse, its now audible at higher ambient temps (29C) and has an associated intermittent high frequency resonance over 60 km/hr. It actually sounded like an exhaust note of an ICE vehicle. I made a video recording in the motor bay, its clearly not right. I drove back to discuss with the service advisor. He heard the recording, has to talk to the tech next week and I guess we will see what happens next. I have to admit its getting kinda annoying and big waste of my time.

The next step should be to replace the motor, at least that is what my dealer advises me. I am surprised they gave it back to you in that condition . So aside from the resonance noise, the tapping sound is worse? If so, does it make the tap sound at low speed only like before or at higher speed as well?

 

[KiwiME]

Frankly, the half-turn idea seemed no better than using witchcraft to me so I'm not surprised. No doubt they'll get it corrected eventually.

 

[apu]

The next step should be to replace the motor, at least that is what my dealer advises me. I am surprised they gave it back to you in that condition . So aside from the resonance noise, the tapping sound is worse? If so, does it make the tap sound at low speed only like before or at higher speed as well?

Its worse in the sense that it is more frequent now and not just when the ambient temp is cooler around 10-12C, and yes its predominantly audible at low speed but I suspect that the high speed resonance sound is just a manifestation of the tapping at a higher velocity.

I am disappointed but not surprised that they felt it was fixed and the job was well done. Its been over 2 months since they first diagnosed the problem. I know what needs to be done but I feel like I have to constantly yet tactfully prompt the dealer's service department to escalate this. I'm thinking that should not have to be my job. Between the 3 instances of the flat 12 volt battery (including one that required tow in the middle of winter) which they tried to blame on the HID lights or the my battery independent dash cam, software recall and 2 separate visits for the ticking noise I am starting to feel I know the service department a little too intimately considering I have only owned the car for 6 months.

 

[Jamas]

...predominantly audible at low speed but I suspect that the high speed resonance sound is just a manifestation of the tapping at a higher velocity.

That's been my belief as well. I always use the example of the baseball card in the bicycle spoke. Higher speed leads to a high speed resonance sound.