Knocking Noise When Braking Solved

Hello! I'm making this post because I've seen a number of threads with this same exact issue with their dealers giving them the runaround (mine did too) and I'm hoping this will help someone else get their car fixed!

TLDR; the brake pad assembly wasn't sitting properly and causing the brake to skip. Probably an error during manufacturing.

My car has been making a knocking sound when the manual brakes kick in. Made me think it was the brake pads or calipers not engaging properly. I saw suggestions it could be due to rust but it wasn't the case for me. Took it into the dealer for them to do a brake inspection. Instead of doing an inspection they drove it around a few times and were quick to blame my Ioniq tumbler I put in the glove box when I dropped it off (lol) and not do a proper inspection. I was insistent and also noticed via Blue Link they were driving around with the fans and defrosters on, and told them to turn them off and do an actual brake inspection. Of course they heard it then.

I was told it was because the front passenger brake pad/assembly wasn't sitting properly, annoying but 100% safe to drive. I was told it was a manufacturing defect but not covered under warranty -- I will be able to get it fixed for no cost since I'm still under 5k miles. Have to wait for the parts to come in. Hope this helps anyone else who has had this issue and was told by their dealership they didn't know what it was!