What was required in order to convince the dealer to agree to the replacement? How many trips to the dealer? Once they finally admitted the issue, how long did the replacement take?
Fourth trip to the dealer did the trick.
First time, I dropped off my car to the dealer I bought my car from in California and they didn't hear the noise. I wasn't present so I couldn't show them what noise I meant. They told me to come back once the noise was more apparent when I picked up the car. This was at 4,000 miles.
Second time was to a different dealer back in Illinois (went back due to covid). They confirmed the noise but didn't know what it was. They wanted me to drop off the car. I was hesitant because they only have one EV certified tech, the tech was recently certified and never worked on an EV before, they had no rentals, and my parent's house was over 25 miles away.
Third time was to another dealer closer to my parent's house. They heard the noise and I dropped off my car there. The tech did his own diagnostic test, ignoring everything I told the service manager, and concluded it was a wheel bearing issue even though the sound goes away on neutral. They didn't open a tech line with Kia even though I was adamant it wasn't a wheel bearing issue. The car showed no signs of a wheel bearing issue other than cosmetic damage on the hubcap. They had my car for five days before I took it back. This was at 17,000 miles.
Fourth time, I brought it back to the dealer I bought my car from in California and showed them the issue. They heard it and opened a tech line with Kia. It took 19 days in total from when I dropped off the car to when I got my car back with the new motor. They confirmed there was no damage to the wheel bearing. They were very hush hush when I asked how many other customers encountered the same issue. This was at 21,000 miles.
The "muffler" noise at high speeds got louder (clicking noise at low speed remained the same) and regen felt weaker as time passed. I was worried the drivetrain could fail during the trip from Illinois back to California since we were climbing up the Rockies. I wanted it fixed beforehand but the Niro EV isn't officially sold in Illinois so can't expect much from the dealerships there. Thankfully we arrived back in California without any issues. This could've been resolved on the very first trip at 4,000 miles if Kia issued a TSB. Too bad we have to deal with the bs from inexperienced and greedy dealerships.