Disappointed (gearbox replacements)

I can assure you I am not an aggressive driver. I rarely tromp it, and almost all my driving is in ECO mode.

 

Yes, the Kona's advertised motor torque of 40.3 kg-m exceeds the rating of all those offerings. I can only assume that the published ratings are for continuous duty based on heat dissipation while the allowable maximum intermittent torque is higher, based on structural strength. That would typically be how a gearbox is rated.

I'll just note that the advertised eNiro gear ratio matches the G1F30 model but photos I've seen of a replacement eNiro gearbox look the same as what's in the Kona. There's certainly no reason why a different ratio couldn't be fitted, or it's simply an error in the Niro specifications.

It seems to me that this failure is due solely to a defective bearing rather than a fundamental gearbox design flaw. But, bearings normally have very tightly controlled quality and this sort of failure mode is puzzling and not mentioned in any forensic analysis guide I've seen.

I tend to agree that the more common clicking issue is a separate defect as the connection with motor replacements is convincing evidence.

 

After sleeping on it, I have one further thought. One missing roller shouldn't have caused as much slop as we were seeing when he was pushing on the thing with a wrench. The adjacent rollers still ought to have been able to prevent any side-to-side movement.

In fact, I am wondering if with the amount of slop seen in the video, that the thing simply fell out after the gearbox had been assembled (no idea when or where it ended up). Any preload that may have been present at one time seems like it is long gone.

 

The epic amount of radial play must have come from the inner raceway wearing down, as he seems to be showing us. That would also explain why the volume of metallic debris seemed to be far more than one roller's worth.

 

Could it just be that the seal between the half-shaft and the gearbox failed to keep some amount of dirt from getting into the gearbox?

 

Well, rolling element bearings are fairly resistant to debris, even if dirt could get in. As you can see the ball bearings appear to have survived all that (presumed hardened) steel running around in the oil. Hydrodynamic ('plain') bearings on the other hand (used in ICE engines as I'm sure you're aware) die very quickly when particles are present.

 

Доброго времени суток друзья, хочу внести некоторую ясность в видео с ремонтом КПП. Мастер в поисках причины снял с конического подшипника один ролик и обнаружил износ внутренней обоймы, сделав вывод, что это результат некачественного металла. Я нашел координаты этого мастера и пытаюсь установить с ним связь и позаимствовать ремонтные процессы.

 

Mystery solved; Thank you! (Спасибо большое)

 

From Google Translate:

Good day friends, I want to bring some clarity to the video with the checkpoint repair. The foreman, in search of the cause, removed one roller from the tapered bearing and found wear on the inner race, concluding that this was the result of poor-quality metal. I have found the coordinates of this master and am trying to communicate with him and borrow repair processes.

 

I'm a KONA EV owner from China.I think my car has the same problem with you.I can hear the noise,a sound not the motor,not the tires.I have gone to the dealership,but there is no fault code。Kona EV in China named Encino,options have some difference