KGCD807XBL02 KitchenAid Cooktop - Overview

As others reported, there are 2 torx screws that need to be removed so that the burner element can be removed. One came out with a little effort, the other one did not as it was corroded. After breaking a torx bit, a second torx bit succeeded in breaking off the screw head. This then required a drill to drill out the broken shaft and th ... Read more en rethreading the screw hole. On to the ignitor replacement. The tiny screw holding the ignitor was corroded and would not come out. It too had to be drllled out and rethreaded. It was a 1/3" #4 screw with fine threads. Had to get it an appliance repair store as the local hardware places don't carry fine threaded screws. Finally got it all put back together after a week. My advice before ordering an ignitor is make sure you can take the current burner off the cooktop first to do the repair in the first place. BTW, the ignitor I ordered came quickly and was the correct part!

Firts I removed the 2 screws that held the burber in place. Then I lifted the burner up & disconnected the wire that connected to the ignitor. Then I removed the one screw that held the ignitor to the burner. I then reversed these steps, replacing the cracked ignitor with the new one, replaced the screw holding it to the burner, then reco ... Read more nnected wire, returned the burner to the stove and replaced the two screws that held it. All Done!

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 ... Read more 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.