Hyundai Sonata: Clutch Engagement Fork and Engagement Bearing Repair procedures - Dual Clutch System - DCT (Dual Clutch Transmission) SystemHyundai Sonata: Clutch Engagement Fork and Engagement Bearing Repair procedures

Removal
1.
Remove the dual clutch transmission from the vehicle.
(Refer to DCT System - "DCT)
2.
Remove the dual clutch assembly.
(Refer to Dual Clutch System - "Dual Clutch Assembly")
3.
Remove the clutch engagement bearing 1 (A) and 2 (B).

4.
Remove the clutch engagement fork (A) and engagement bearing sleeve (B).

Installation
   
Apply coat of grease when installing the clutch fork.

Spec grease: CASMOLY 9508
Amount: 0.2g

1.
Install the clutch engagement fork (A) and engagement bearing sleeve (B).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   
Check dowel pins (A-2ea) when installing the fork assembly. Replace the dowel pin with new part if it is damaged or deformed.
Take caution of the direction of fork assembly shaft when installing.

2.
Install the engagement bearing 1 (A).
   
Align the fork with the bearing plastic guide direction.

3.
Install the engagement bearing 2 (A).
   
Take caution and make sure that the bearing plastic stopper (B) is settled in the sleeve (C).

   
Apply coat of spec grease on the 1st input shaft spline (A) after installing the bearing.
Apply proper amount of transmission oil on the 2nd input shaft spline (B).
(Be careful not to get oil on the spline when applying coat of oil.)

Spec grease: CASMOLY 9508
Amount: 0.15 ~ 0.25g

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