KGCU407VSS01 KitchenAid Cooktop

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.

Used cooktop creme, oven cleaner and Mr. Clean sponges. After many days of working on the surface, we were able to remove 99% of the sauce.

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 rem ... Read more oving 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!