2022-2025 Hyundai Ioniq 5 Tailgate Rattle & Noise TSB 24-BD-012H

Owners of 2022-2025 Hyundai Ioniq 5 (NE EV) vehicles may notice unusual "rattle and friction noises from the tailgate while driving." This issue can be distracting and indicate a need for adjustment or component replacement in the tailgate assembly. Hyundai has released Technical Service Bulletin (TSB) 24-BD-012H to provide a solution for this specific concern.

This TSB, identified as 24-BD-012H, supersedes a previous bulletin, TSB 23-BD-006H-1, indicating an updated procedure and parts for the rework. The primary goal of this service bulletin is to eliminate the tailgate rattle and friction noise by adjusting the gap between the tailgate and the vehicle body.

Symptoms of Tailgate Rattle and Friction Noise

The main symptom reported by owners is the presence of "rattle and friction noises from the tailgate while driving." These noises typically originate from the rear of the vehicle, specifically around the tailgate area. The sounds can vary in intensity and may be more noticeable on uneven roads or during certain driving conditions.

What Hyundai is Doing: TSB 24-BD-012H

Hyundai has issued TSB 24-BD-012H to guide technicians through a rework procedure. This bulletin provides detailed instructions to adjust the gap between the tailgate and the vehicle body, which is the root cause of the "rattle and friction noises from the tailgate while driving." The procedure involves replacing specific guide bumpers and making precise adjustments to the tailgate striker and overslam bumpers.

Repair Procedure Summary

The repair outlined in TSB 24-BD-012H involves several key steps to address the Hyundai Ioniq 5 tailgate rattle. First, technicians will replace the tailgate side guide bumpers and the outer side panel guide bumpers. This involves removing existing bolts, transferring them to new guide bumpers, and installing washers to ensure a proper fit. The new guide bumpers must be oriented correctly, with specific tightening torques applied (1.8 lb-ft, 22 lb-in, or 2.5 N.m).

Following the guide bumper replacement, the procedure details how to adjust the tailgate striker. This involves loosening the striker bolts by a quarter turn, positioning a striker bar, and gently tapping it with a hammer to achieve the correct alignment. The striker bolts are then tightened to 18 lb-ft (24 N.m). Finally, the tailgate overslam bumpers are adjusted by turning them to fine-tune the gap between the tailgate and the vehicle body, ensuring the tailgate opens and closes properly without noise.

Required Parts and Tools

To perform the repair for the Hyundai Ioniq 5 tailgate rattle, the following parts are specified:

• Guide Bumper Kit: Part Number 81771-GI501QQH. This kit includes washers for the tailgate side panel (6 left, 6 right, plus 4 extra), two guide bumpers for the tailgate side panel, and two guide bumpers for the side outer side panel.
• Replacement Bolt(s): Part Number 81456-G8000. These bolts are only required if the original bolt heads are damaged during removal.

Special tools mentioned include a striker bar and a hammer for adjusting the tailgate striker.

Important Warnings for Owners

Owners should be aware of specific conditions related to this repair:

• Specialized Repair: "To avoid any potential damage to IONIQ vehicles, IONIQ repairs can only be performed at IONIQ certified dealers." This means that only dealerships with specific training and equipment for IONIQ electric vehicles can carry out this service.
• Safety Caution: During the adjustment of the tailgate striker, there is a risk of "Hand injury or damage to the bumper/trim may occur if the striking bar is not properly positioned on the tailgate striker." This highlights the precision and care required for the procedure.

Warranty Information

For this tailgate rattle and friction noise adjustment, the operation code is 40D150R0, with an estimated operation time of 0.4 man-hours. The causal part is identified as 81771-GI501QQH. Claims should be submitted on the Claim Entry Screen as a "Campaign" type. If a part needs replacement and is under warranty, a separate claim should be filed. For out-of-warranty parts, a Prior Approval request for goodwill consideration is necessary. Technicians are required to submit repair validation photos, including VIN, mileage, and photos of the repair, as part of the Digital Documentation Policy.

Next Steps for Owners

If your 2022-2025 Hyundai Ioniq 5 is experiencing a tailgate rattle or friction noise, you should contact an authorized IONIQ certified Hyundai dealer. Inform them about the symptoms you are experiencing and mention Technical Service Bulletin 24-BD-012H. The dealer will be able to diagnose the issue and perform the necessary rework to resolve the Hyundai Ioniq 5 tailgate rattle.

Source: NHTSA ID 11008918