KCGD500GSS05 KitchenAid Cooktop - Instructions

This problem was driving me crazy for months. Of course, after I bought and installed the part and it still was not fixed I finally found a website that told me how to fix the clicking. The problem is that the removable head burners (#8 on the top assembly diagram) are not making good electrical contact with the base burners (#22). What I did was grab the head burners and grind them back and forth into the base burners with the weight on the heal of my hand. Steel wool or sandpaper would work too--you just want to clean the surfaces to restore electrical contact.
If you still want to know how to replace the spark module start by removing #24. This will allow the removal of #9 (after you take the knobs off). You may have to do some fiddling cause the rubber gasket is sticky. Next there are 2 obvious regular screws for #14 and 2 not so obvious star screws in the space where the burner valves are. After #14 is off there are 2 screws on the spark module to be removed and one that you can't loosen that is in a slot. You wriggle the module out of that one.

Since the problem would only occur when the right front burner was on, I first replaced the ignitor, but the problem persisted. To replace the spark module I had to pull the range out of the nook it is in in the counter top. Then (after ensuring that the power was off) I removed the back cover. The spark module was easily located and removing two screws and disconnecting a few wires liberated it. The new one went in easily since it is the same part number and an exact match. Put the back on and check that the problem was solved. Done!

Removed the small access cover on the bottom of the cooktop by reaching inside and under the cabinets. Removed the module which was held by two hex head screws, unplugged the wires noting the location and color of the wires. Plugged the wires into the new module in the proper locations as noted previously. Attached the module with two screws, and then attached the cover/access plate with two screws. Problem resolved, repair was easy.

Installed new spark module by removing back panel of stove. Removed two screws holding old module. Disconnect lines, marking colors. Installed new. Problem not solved. Out $128 since new module was not returnable after install.
Called Judd and Black service department. Tech came on service call. Said it was bad gas valve. They ordered part. Than needed two weeks to install. I installed it and problem persisted. Could not return part because I installed it myself. Out $180. I had cleaned ignitor with alcohol from top. Took apart cooktop and cleaned from bottom. Problem fixed for free. Out over $500 in parts and labor.

remove two screws then unplug the wires put the wires back on the new one

First step is to turn gas off to cook top and also disconnect power to the unit. Than using a crescent wrench disconnect the gas line going to the unit from the Regulator. Than again using the crescent wrench disconnect the regulator from the bottom of the unit. Next remove the nipple that connects the gas line to the regulator from the old unit. Apply new pipe dope to the threads and screw it into the new one and tighten down. Next install the regulator to the unit and install the gas line to the regulator. once done with the install you can now plug the unit in and turn on the gas. You are now ready to use the cook top again