2023-2024 Hyundai Ioniq 5, Kona Electric Motor Grinding Noise TSB

Symptoms

Owners of certain 2023-2024 Hyundai Ioniq 5 and 2024 Kona Electric vehicles may notice an unusual "grinding/whining noise" during vehicle operation. This noise originates from the Motor and Reduction Gear System (MGDU), which encompasses both the motor and reduction gear.

Diagnosis / Trigger Conditions

This condition is attributed to an incorrect amount of oil or fluid present in the Motor and Reduction Gear System (MGDU) from the manufacturing process. The service campaign, identified as 25-01-042H, addresses this by specifying a procedure to correct the fluid level.

Repair Procedure Summary

To resolve the grinding or whining noise, the service procedure involves draining the existing oil from the Motor and Reduction Gear System and replacing it with new, specified fluid. The steps vary slightly depending on the vehicle model and the specific motor unit (front or rear).

For the IONIQ 5 (NE EV) Front Motor and Reduction Gear System, technicians will perform an oil replacement, filling with 3.0 liters of new fluid. For the IONIQ 5 (NE EV) Rear Motor and Reduction Gear System, the fill volume is 2.9 liters. The Kona Electric (SX2 EV) Front Motor and Reduction Gear System requires 2.3 liters of new fluid.

During this process, it is crucial that the existing drain plug gasket and filler plug gasket are replaced with new parts. They MUST be replaced and Do NOT reused. All fasteners, including the drain plug and fill plug, must be tightened to a specific torque of 38 lb-ft (46 N.m) to prevent future issues.

Required Parts

Technicians will need the following parts for the oil replacement:

• Gasket-Magnetic Plug: Part Number 45323-39000QQH (2 each)
• ATF SP4M-1 (Auto Mission Oil): Part Number 04500-00125QQH (Front MGDU: 3 each, Rear MGDU: 3 each)

Important Warnings

Hyundai has issued several critical directives regarding this service campaign:

• Dealers must perform this service campaign on all affected vehicles prior to customer retail delivery. It must also be performed whenever an affected vehicle is in the shop for any maintenance or repair.
• To avoid any potential damage to IONIQ vehicles, this service campaign can only be performed at IONIQ certified dealers.
• Applying the recommended torque to all fasteners is essential to reduce potential issues from occurring after the service procedure.
• The existing drain plug gasket and filler plug gasket MUST be replaced with new parts. Do NOT reuse old gaskets.

Owner Action

If you own a 2023-2024 Hyundai Ioniq 5 or a 2024 Kona Electric and experience a "grinding/whining noise" from the motor area, or if you wish to confirm if your vehicle is part of this service campaign, you should contact an IONIQ certified Hyundai dealer. The dealer can check your VIN in their system (WebDCS) to determine if the campaign 25-01-042H is open for your vehicle. This service campaign will be performed free of charge under warranty.

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Source: NHTSA ID: 11020692