Concerns - Popping/Creaking Noise from Sunroof

[Marc Collins]

I picked up my car today after the dealership replaced the sunroof rails even though they wanted to keep it another week or two to wait for the seat module to arrive from Korea (I will take the car back after the part has arrived). On the drive home there was no familiar creaking sounds coming from above so fingers crossed the problem has not just been temporarily fixed.

Based on my experience with the "washer fix," unless they put some soft material between the rails and the metal of the car, or, did some version of the washer fix, the creaking will just return in the future the same as it did with the original rails. Or, maybe they are rails that have been redesigned (doubtful)? It would be great to find out from the dealer for our current benefit and your future benefit if the problem recurs.

Only a few people have managed to be forceful enough to get KIA to replace their rails. Ironically, this may not even be needed, but KIA is too lazy to pursue and investigate simpler solutions. They would rather do nothing for the 99% and spend a fortune to shut up the complaints of the most vocal 1%. I am glad you got them to respond, but the further irony is that for every happy customer with an expensive rail replacement solving their problem, the more "blind and deaf" they will become to others complaining because under no circumstances does KIA want to:

• acknowledge this is a widespread problem
• acknowledge that the proper fix is a hugely expensive procedure
• recall the car
• encourage others to come forward to get their creaking addressed

Even the washer fix involves enough labour and risk of damaging the existing parts of the car that KIA will not disseminate the information to dealers in a co-ordinated manner. Business as usual will remain to deny there is a problem until confronted with persistent truth, then claim it is common/normal/part of the design. This will address the vast majority of customers who are less picky and too busy/sane to spend hours of frustration fighting with their dealer or KIA HQ. Standard operating procedure in the automotive industry, not specific to KIA.

 

[eyan869]

So, I did a slight variation on this "fix." When I looked carefully at how all this stuff is bolted down, I concluded that the "other" bolt (to the upper right as seen in the pic above) is actually the one more likely to benefit from a forced gap between the body metal and sunroof rail metal. The front outer corner position is also plastic and can easily break if pressure is applied.

I removed the circled bolt, the "other" bolt and the next bolt toward the rear along the same side of the rails as the "other" bolt because without removing that third one, there would be no way to get any leverage to raise the rail enough to insert a washer under the "other." I used two left-over washers I bought to fix the rear hatch rattle: 5/16ths thinner than usual zinc. I would guesstimate two of these washers are the thickness of the one in the pic above. I used two thin ones because I wanted to have the option to later add a single washer to the rearward bolt position if the two thin ones at the front did not work.

Repeat for the other side of the car.

Result: silence...for the first time in more than a year. I am completely shocked...the car sounds like it did when it was brand new. No rattles, ticks squeaks, whatsoever.

Thanks to all on here who persevered and shared stories, especially @cwatt79. I am also heartened that my theory about metal rubbing against metal was correct. The roof itself is not the issue--it's the rails. Hence why every adjustment or greasing or maritime lube did nothing (or made things worse).

Hope this is helpful to others who might want to now try this 59-cent solution to an unbelievably agonizing customer service nightmare. But be very careful with removal and replacement of the pop-up wind/bug screen...that is the tricky part of this. Hopefully some will be able to force their dealers to do this procedure (as it sounds as though some already are, but perhaps not doing it in the most effective manner).

Tried This fix on my Canadian 2019 GT Limited. Worked perfectly!!! Thank you so much Marc and cwatt79!

 

[TimT]

So an update on my roof, all of the warranty things were slightly delayed due to the vacation period of july, but now my car was in for a day. The dealership got a visual guide from Kia Europe on how to determine which part of the frame is rattling and needs attention. They tested for a day and the conclusion was that the whole frame is rattling. Then Kia Europe gave them a guide on how to remove the frame, install "softening cushions" there, which I presume are a more hardcore version of 3m tape and then re-install the frame so that all the structrual integrity etc remains proper. Gonna be trying out this in a few weeks since they are now waiting for the spare parts they need for it.
If this does not work then the next option is to order a whole new frame but that would mean a warranty cost of 3000€ + labour cost for the Kia rep.

 

[Marc Collins]

So an update on my roof, all of the warranty things were slightly delayed due to the vacation period of july, but now my car was in for a day. The dealership got a visual guide from Kia Europe on how to determine which part of the frame is rattling and needs attention. They tested for a day and the conclusion was that the whole frame is rattling. Then Kia Europe gave them a guide on how to remove the frame, install "softening cushions" there, which I presume are a more hardcore version of 3m tape and then re-install the frame so that all the structrual integrity etc remains proper. Gonna be trying out this in a few weeks since they are now waiting for the spare parts they need for it.
If this does not work then the next option is to order a whole new frame but that would mean a warranty cost of 3000€ + labour cost for the Kia rep.

It will work and is the right solution compared to the insert-washer trick that also works. After realizing that the washers resolved the ticking and creaking (see above), it was obvious to me that some form of cushioning or rubber washers at each connection point should have been designed-in from the outset.

Please confirm here after you get it done so the rest of us can go get our dealers to do it, too!

 

[Aurelian]

Happy to report that 90% of my sunroof noise issue (by my OCD standards) on my 2018 GT1 was eliminated by the washer fix first detailed by cwatt79 and Marc Collins.

Previously I had already cut up one of those silicone cardholders that you stick on the back of your phone, to make two small thin pieces to stick onto the depression on each side where the sunroof feet enter when it closes. This helped with some of the most egregious vibrations, but there was still a noticeable, constant level of noise. I misinterpreted this as creaking and flexing noise, and spent a lot of time tightening bolts and greasing every part of the roof and the seals around the roof.

This time I bought 4 x 5/16 rubber washers (literally $2 at Lowes), removed the sunroof bug deflector, and unscrewed enough rail bolts on each side to insert the rubber washers under the two front bolt positions on each rail. At first I put all the bolts back in pretty tightly, but after a couple hours of testing it appears that may reduce the solution's effectiveness since the whole point here is to achieve some clearance between the sunroof rail and the body metal. In the end I left each bolt finger tight, and made sure the washers in the front were not squeezed or distorted by the bolts.

I left the bug deflector off in the end as well - when you disassemble it you find it has metal on metal parts that seem like another potential noisemaker. Anyway I almost never open the sunroof glass.

Previously I was one of those Stinger owners who drove with the sunroof cover closed 95% of the time because the sunroof ticking was loud enough to be heard even with music on, and especially so with the cover open. Now the vibrations are reduced to a level where I have to be attentive to hear it, and only over broken or rough pavement - probably not enough to notice with even low volume music on.

Again props to cwatt79 and Marc Collins for getting to the bottom of this!

 

[FitR6]

I have had mine back about 2 weeks after getting the sunroof rails replaced when all other measures failed, and so far so good regarding noise issues. Now I need to take it back again to get the retracting seat issue fixed after they just replaced the seat module which didn't correct the problem. Grrrr. Its never ending.

 

[Marc Collins]

I have had mine back about 2 weeks after getting the sunroof rails replaced when all other measures failed, and so far so good regarding noise issues. Now I need to take it back again to get the retracting seat issue fixed after they just replaced the seat module which didn't correct the problem. Grrrr. Its never ending.

When you go back, can you confirm whether the new rails install included some form of bushing/gasket/washers/etc.? If so, 99% chance that's all that was required in the first place with the existing rails. If not, 99% chance your creaking will be back after some period--as has happened with all our cars that didn't creak initially.

If they did something, we need those part numbers so we can get the rest of the dealer network to wake up and start fixing this problem instead of sending people in useless circles of frustration.

 

[FitR6]

When you go back, can you confirm whether the new rails install included some form of bushing/gasket/washers/etc.? If so, 99% chance that's all that was required in the first place with the existing rails. If not, 99% chance your creaking will be back after some period--as has happened with all our cars that didn't creak initially.

If they did something, we need those part numbers so we can get the rest of the dealer network to wake up and start fixing this problem instead of sending people in useless circles of frustration.

Washers were replaced two visits earlier, making the noises worse.

 

[Marc Collins]

Washers were replaced two visits earlier, making the noises worse.

Doesn't answer my question. Which I am asking precisely because the do-it-yourself washer fix is undoubtedly not the best solution. Some cushioning at every connection point or under the entire rail system would be best, so wondering if they did that. I stand by my prediction that if they simply replaced what was put in at the factory, it will be a temporary "solution."

 

[FitR6]

Doesn't answer my question. Which I am asking precisely because the do-it-yourself washer fix is undoubtedly not the best solution. Some cushioning at every connection point or under the entire rail system would be best, so wondering if they did that. I stand by my prediction that if they simply replaced what was put in at the factory, it will be a temporary "solution."

Your earlier question needed to be clearer. You asked if new rails included some form of washers. What are you actually asking and I will attempt to find out from the incompetent people at Kia? Regards cushioning (?), the seals were also replaced in an earlier "fix", with zero result.

 

[Marc Collins]

Your earlier question needed to be clearer. You asked if new rails included some form of washers. What are you actually asking and I will attempt to find out from the incompetent people at Kia? Regards cushioning, that was also replaced in an earlier "fix", with zero result.

There is no cushioning on my car, so I may have wrongly assumed that was the case for all. If they already replaced cushioning on your car (i.e., you are on second batch when I/the rest of us have none), then it must have a different issue than most of the rest of ours. I have been advocating to put some form of cushioning in, since simply separating the metal rails from grinding and shimmying against the metal car roof resolves the creaking most of us get. You may have cracked rails that are scrunching into themselves?

 

[FitR6]

There is no cushioning on my car, so I may have wrongly assumed that was the case for all. If they already replaced cushioning on your car (i.e., you are on second batch when I/the rest of us have none), then it must have a different issue than most of the rest of ours.

I'm sure we can all agree that ANY issue is frustrating and shouldn't be this difficult to remedy. Im having another issue elsewhere in the car that they also haven't fixed and Im dealing with Kia Australia right now about their consistent lack of fixing issues.

 

[FitR6]

There is no cushioning on my car, so I may have wrongly assumed that was the case for all. If they already replaced cushioning on your car (i.e., you are on second batch when I/the rest of us have none), then it must have a different issue than most of the rest of ours. I have been advocating to put some form of cushioning in, since simply separating the metal rails from grinding and shimmying against the metal car roof resolves the creaking most of us get. You may have cracked rails that are scrunching into themselves?

I have taken your wording of "cushioning" to mean the seals and have amended my previous post. Sorry if I misinterpreted.

 

[Dodger Blue]

My car's sunroof rattle has become really bad over the last few months, to the point where I get a vibrating noise even at idle. I agree with the sentiments further upthread that Kia needs to bite the bullet and just recall the car already. They "fixed" my issue once and the rattle came back within 500 miles, now it's so much worse than before and I don't really trust them to do much about it.

 

[FitR6]

My car's sunroof rattle has become really bad over the last few months, to the point where I get a vibrating noise even at idle. I agree with the sentiments further upthread that Kia needs to bite the bullet and just recall the car already. They "fixed" my issue once and the rattle came back within 500 miles, now it's so much worse than before and I don't really trust them to do much about it.

Took them 9 tries to halt my noises, and Im not confident its a permanently fix. I have been in contact with Kia Australia about it who I demanded compensation for my wasted time having my car in for repairs so often. I told them how common this issue is, and they told me they are not aware of that. I advised them to go onto this forum to see how many people are complaining of this issue, and the response was "it's not up to Kia to do such a thing. Its up to the owners of these cars to submit these issues formally". Ummm.... isn't taking you car in for repairs submitting these issues formally? He told me Kia have the best warranty because they want to ensure the best support for their cars, and I told him its because it takes them 7 years to FIX the damn issues!

 

[Dodger Blue]

Took them 9 tries to halt my noises, and Im not confident its a permanently fix. I have been in contact with Kia Australia about it who I demanded compensation for my wasted time having my car in for repairs so often. I told them how common this issue is, and they told me they are not aware of that. I advised them to go onto this forum to see how many people are complaining of this issue, and the response was "it's not up to Kia to do such a thing. Its up to the owners of these cars to submit these issues formally". Ummm.... isn't taking you car in for repairs submitting these issues formally? He told me Kia have the best warranty because they want to ensure the best support for their cars, and I told him its because it takes them 7 years to FIX the damn issues!

How does one do a formal submission? Did they tell you the process? I bet if we all banded together to put it to them in writing they would get the freaking hint.

 

[FitR6]

How does one do a formal submission? Did they tell you the process? I bet if we all banded together to put it to them in writing they would get the freaking hint.

He just said that for here in Australia, Stinger owners need to formally complain to Kia Australia if dealerships are consistently not rectifying a problem. What will they do? Probably not much.

 

[Duox]

Hey all, after the dealership basically refused to service my car by dragging their heels, I am going to try the washer fix.

Besides the one picture earlier, are there any other visual guides to the fix?
Is there a good step-by-step guide to the fix, YouTube video ideally, or at least the wind screen / bug net removal part (mentioned to be the part risking damage the most)?
What washer should I buy? Looks like a metal washer 5/16 M8 is the one used for the trunk fix, and the trunk fix washers are the same used to fix the sunroof.

Edit: I attempted the washer fix as described by others. It's really straight forward once you see what needs to be adjusted, so my original comments are no longer relevant. I put two washers, one each under the front two bolts on each side. I also kept the bug guard off. As before, at 55mph+, the sound remained. Unfortunately, I don't know if any other DIY fix. And the dealership here won't help. Officially SOL.

 

[rockydil]

Here I am with the same ticking noise coming from the passenger side rails. 2021 GT Limited (Canada). After three appointments with the dealer's service shop (waste of time) I am trying to fix myself.

I tried the fixes in this thread with no luck. I can generate the sound I hear while rolling by pushing down on the front corner of the open sunroof. By doing that continually and feeling around at the same time, I've found the culprits.

The issue is where plastic meets metal under the three bolts on the left side of my picture.

If I gently press my finger down in that area the creaking stops. I've tried loosening the bolts, adding rubber washers, and adding foam and putty spacers, with no luck. Only my finger gently pushing down works, and I can't drive like that lol.

Any ideas?

 

[Kamauxx]

Here I am with the same ticking noise coming from the passenger side rails. 2021 GT Limited (Canada). After three appointments with the dealer's service shop (waste of time) I am trying to fix myself.

I tried the fixes in this thread with no luck. I can generate the sound I hear while rolling by pushing down on the front corner of the open sunroof. By doing that continually and feeling around at the same time, I've found the culprits.

The issue is where plastic meets metal under the three bolts on the left side of my picture.

If I gently press my finger down in that area the creaking stops. I've tried loosening the bolts, adding rubber washers, and adding foam and putty spacers, with no luck. Only my finger gently pushing down works, and I can't drive like that lol.

Any ideas?

Have you tried this? Sunroof Rattle Fix