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

Removal
1.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechnical System - "Air cleaner")
2.
Remove the TCM.
(Refe to Dual Clutch Transmission Control System - "TCM")
3.
Remove the battery and tray.
(Refer to Engine Electrical System - "Battery")
4.
Disconnect the connectors in the illustration below.
(A) Inhibitor switch connector
(B) Clutch actuator connector
(C) Gear actuator solenoid connector
(D) Input shaft speed sensor connector

5.
Disconnect the gear actuator motor connector (A).

6.
Remove the ground (A) and wiring bracket (B-2ea) after removing the bolts.

7.
Remove the control cable (B) after removing the nut (A).

8.
Remove the ground (A) after removing the bolts.

9.
Loosen the transmission upper mounting bolts (A-2ea) and the starter mounting bolt (B-1ea).

Tightening torque
(A), (B) : 42.2 ~ 53.9 N.m (4.3 ~ 4.5 kgf.m, 31.1 ~ 39.8 lb-ft)

10.
Assemble the engine support fixture(beam No.: 09200-38001 or 09200-3N000, supporter No.: 09200-2S000).
(Refer to Special Service Tools - "Engine support fixture assembly drawing")
11.
Using the engine support fixture, hold the engine and transaxle assembly safely.

12.
Remove the dual clutch transmission mounting bracket cover (A).

13.
Remove the dual clutch transmission mounting support bracket bolts (A).

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.8 lb-ft)

14.
Remove the dual clutch transmission mounting support bracket (A).

Tightening torque :
58.8 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

15.
Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
16.
Remove the front drive shaft.
(Refer to Driveshaft and axle - "Drive shaft assembly")
17.
Remove the sub frame.
(Refer to Suspension System - "Sub Frame")
18.
Loosen the intercooler inlet pipe mounting bolts (A-2ea).

Tightening torque :
19.6 ~ 26.4 N.m (2.0 ~ 2.7 kgf.m, 14.4 ~ 19.5 lb-ft)

19.
Separate the vacuum pump (A) from the transmission by loosening the bolts (B-2ea).

Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)

20.
Loosen the starter mounting bolt (A).

Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 4.5 kgf.m, 31.1 ~ 39.8 lb-ft)

21.
Support the transmission safely by using the jack.
22.
Loosen the transmission lower mounting bolts (A-5ea).

Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 4.5 kgf.m, 31.1 ~ 39.8 lb-ft)

23.
After separating the transmission from the engine, remove the transmission by lowering the jack slowly.
   
Be careful not to damage other system or parts near by when removing the transaxle assembly.
Installation
1.
Install in the reverse order of removal.
   
Matters that require attention when installing the dual clutch transmission (DCT) to engine
1.
Check the pilot bearing (B) and external damper (A) on the side of engine for any dents, damages and deformations before installing the DCT.

2.
Align the external damper spline (A) with the dual clutch spline (B).

3.
Insert the input shaft (A) to the engine pilot bearing (B) and then assemble the DCT to the knock bushing on the engine side.

4.
After adhering the DCT with engine by pushing the DCT, tighten the mounting bolts after checking that there is no gap (less than 2mm) between the clutch housing and the engine block.
(If the bolt is tightened while there is a gap, then the spline of external damper or clutch will be damaged or broken.)

2.
Follow the separated each procedure as below according to reinstallation or replacing with a new dual clutch transmission.
In case of the reinstallation
A.
If the differential oil seal is damaged and oil is leaking, replace the oil seal with a new one. When installing the new oil seal, use the special tool (9430-C1190, 09231-H1100).
B.
After installing the DCT, check the oil level after refilling the DCT with oil.
C.
Clear the diagnostic trouble codes (DTC) using the GDS. Even though disconnecting the battery negative terminal, the DTCs will not be cleared. So, be sure to clear the DTCs using the GDS.
3.
In case of the replacing with a new dual clutch transmission.
A.
After replacing the new DCT, it need not oil refill & level check procedure because oil is already filled with specified quantity inside new DCT.
B.
Clear the diagnostic trouble codes (DTC) using the GDS. Even though disconnecting the battery negative terminal, the DTCs will not be cleared. So, be sure to clear the DTCs using the GDS.
C.
Perform clutch characteristics input procedure using the GDS. (One of two procedure must be performed.)
Clutch characteristics input (Manual Teaching)

Clutch touch point learning

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