Hyundai Sonata: Clutch Actuator Assembly Repair procedures - Dual Clutch Transmission Control System - DCT (Dual Clutch Transmission) SystemHyundai Sonata: Clutch Actuator Assembly Repair procedures

Removal
1.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechnical System - "Air cleaner")
2.
Remove the TCM.
(Refer to Dual Clutch Transmission - "TCM")
3.
Remove the battery and tray.
(Refer to Engine Electrical System - "Battery")
4.
Disconnect the clutch actuator connector (A).

5.
Remove the under cover.
(Refer to Engine Mechanical Sysmte - "Engine Room Under Cover")
6.
Remove the fork cover after loosening the bolt (A-2ea).

Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

7.
Remove the vacuum pump (B) after removing the bracket mounting bolts (A-2ea).

8.
Remove the stater motor mounting bolt (A) and lower mounting bolt (B).

9.
Fix the clutch engagement fork by rotating a bolt after installing special service tool (09430-A5100).

10.
Remove the clutch actuator assembly from the transmission after loosening the bolt (A-3ea).

Inspection
1.
Remove the clutch actuator.
(Refer to Clutch Actuator Assembly - "Removal")
2.
Install the clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts.

3.
Remove clutch actuator motor (A) and ground bolt (B).

4.
Insert the special service tool (09430-C1302) to ball screw and rotate counter-clockwise until "click" sound is heard.
   
If a “click” sound does not occur, turn the ball screw to the end in the counterclockwise direction.
Be very careful not to turn the screw continually to the counterclockwise direction when it is located at the end, it may cause Actuator damage.

5.
Measure the length (C) from reference plane (A) to the end part of rod (B).

Service Standard : 25 mm (0.9843 in.)

6.
If length of pull rod is about 25mm (0.9843in.) less then replace the dual clutch and the clutch actuator, and the engagement bearing.
Installation
1.
Install in the reverse order of removal.
   
Perform the work procedures for abrasion compensation reset before installing the new clutch actuator assembly. (Refer to Clutch actuator assembly - "Adjustment")
Check the assembled state of the dowel pins (A) before installing the clutch actuator assembly.

Perform the clutch touch point learning procedure using the GDS after replacing the clutch actuator assembly.

Adjustment
   
Perform the work procedures for abrasion compensation reset by referring to the table below.
Item
Specifications
Dual clutch assembly exchange
Initialize
Clutch actuator assembly exchange
Rewind
Dual clutch assembly + Clutch actuator assembly exchange
Not required

How to rewind abrasion compensation
1.
Remove the clutch actuator assembly.
(Refer to Clutch Actuator Assembly - "Removal")
2.
Install the faulty clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts.

3.
Remove clutch actuator motor (A) and ground bolt (B).

4.
Insert the special service tool (09430-C1302) to ball screw and rotate counter-clockwise until "click" sound is heard.
   
If a "click" sound does not occur, turn the ball screw to the end in the counterclockwise direction.
Be very careful not to turn the screw continually to the counterclockwise direction when it is located at the end, it may cause Actuator damage.

5.
Measure the length (C) from reference plane (A) to the end part of rod (B).

6.
Pull the lever (A) until "click" sound is heard and then measure the length to check for pull rod length of faulty clutch actuator (B).

7.
Remove the clutch actuator from the special service tool (09430-C1302).
8.
Install the new clutch actuator (A) on special tool (09430-C1302) and fix the actuator using nuts.

9.
Remove clutch actuator motor (A) and ground bolt (B).

10.
Insert the special service tool (09430-C1302) to ball screw and rotate counter-clockwise until "click" sound is heard.
   
If a "click" sound does not occur, turn the ball screw to the end in the counterclockwise direction.
Be very careful not to turn the screw continually to the counterclockwise direction when it is located at the end, it may cause Actuator damage.

11.
Fix the pull rod to hook (B) and then remove sealing rubber (A).

12.
Insert special service tool (09430-C1300) to the sealing rubber hole and then adjust the length of pull rod to the length of previous clutch actuator pull rod by rotating clockwise.

13.
Pull the lever (A) until "click" sound is heard and then measure the length to check for pull rod length (B).

14.
Install the sealing rubber (A).

15.
Install the clutch actuator motor (A) and ground bolt (B) with the O-ring (C).
   
Check the O-rings (C) and install them carefully.

Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

How to initialize abrasion compensation
1.
Remove the clutch actuator assembly.
(Refer to Clutch Actuator Assembly - "Removal")
2.
Install the clutch actuator (A) on special service tool (09430-C1302) and fixing the actuator using nuts.

3.
Remove clutch actuator motor (A).

4.
Insert the special service tool (09430-C1302) to ball screw and rotate counter-clockwise until "click" sound is heard.
   
If a "click" sound does not occur, turn the ball screw to the end in the counterclockwise direction.
Be very careful not to turn the screw continually to the counterclockwise direction when it is located at the end, it may cause Actuator damage.

5.
Fix the nut (A) after setting the T plates (B) to 49mm (1.9291 in).
6.
Remove the sealing rubber (C).

7.
Insert special service tool (09430-C1300) to the sealing rubber hole and then move to the T plates (A) by rotating clockwise.

8.
Fix the pull rod to hook (B) and install the sealing rubber (A).

9.
Pull the lever (A) until "click" sound is heard and then measure the length again to check for specified length (B).

Specified length : 71.5 mm (2.8150 in.)

10.
Install the clutch actuator motor (A) and ground (B).
   
Check the O-rings (C-2ea) and install them carefully.

Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

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