Hyundai i-30: Dual Clutch Transmission Assembly / DCT (Dual Clutch Transmission)

Hyundai i30 (PD) 2018-2024 Service Manual / DCT(Dual Clutch Transmission) System / Dual Clutch Transmission Assembly / DCT (Dual Clutch Transmission)

Components and components location
Components

1. DCT (Dual Clutch Transmission) assembly
2. DCT support bracket
3. Roll rod support bracket



Repair procedures
Removal
1.
Turn ignition switch OFF and disconnect the battery negative (-) terminal.
2.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechnical System - "Air Cleaner")
3.
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
4.
Remove the ECM.
(Refer to Engine Control System - "ECM")
5.
Disconnect the connectors in the illustration below after loosening the bracket mounting bolt.
A.
Inhibitor switch connector
B.
TCM connector
C.
Speed sensor connector
D.
Gear actuator connector

6.
Loosen the wiring bracket mounting bolt (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

7.
Loosen the ground mounting bolt (A)
Tightening torque:
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

8.
Remove the shift cable (C) after loosening the nut (A) and bolts (B).
Tightening torque :
(A) : 9.8 - 13.7 N.m (1.0 - 1.4 kgf.m, 7.2 - 10.1 lb-ft)
(B) : 19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)

9.
Loosen the mounting bolts and then remove the crankshaft position sensor (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

10.
Loosen the crankshaft position sensor wiring bracket mounting bolt (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

11.
Loosen the transmission upper mounting bolts (A) and starter mounting bolts (B).
Tightening torque :
(A) 42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
(B) 49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)

12.
Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
13.
Install the special service tool (09200-K6100).
(In case of gasoline 1.5 T-GDI)

14.
Assemble the engine support fixture (beam No. : 09200-38001 or 09200-3N000, supporter No. : 09200-2S000, adapter No. : 09200-2W000).
(Refer to Special Service Tools - "Engine Support Fixture Assembly Drawing")
15.
Using the engine support fixture(A), hold the engine and transaxle assembly safely.

16.
Remove the cover (A).

17.
Remove the transaxle mounting bracket bolts (A).
Tightening torque :
88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.8 lb-ft)

18.
Remove the transmission support bracket (A) after loosening the mounting bolts.
Tightening torque :
58.8 - 78.5 N.m (6.0 - 8.0 kgf.m, 43.4 - 57.9 lb-ft)

19.
Remove the engine room under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
20.
Loosen the ground and bracket mounting bolt (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

21.
Remove the intercooler inlet pipe (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)

22.
Remove the roll rod bracket (A) after removing the bolt (B) and (C).
Tightening torque :
(B) : 107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
(C) : 49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)

23.
Remove the roll rod mounting support bracket (A).
Tightening torque :
49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)

24.
Remove the sub frame.
(Refer to Suspension System - "Sub Frame")
25.
Remove the front drive shaft assembly.
(Refer to Driveshaft and Axle - "Front Driveshaft")
26.
Support the transmission safely by using the jack.
27.
Loosen the transmission lower mounting bolts (A, B).
Tightening torque :
(A) 42.2 - 48.1 N.m (4.3 - 4.9 kgf.m, 31.1 - 35.4 lb-ft)
(B) 42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)

28.
After separating the transmission from the engine, remove the transmission by lowering the jack slowly.
  
Be careful not to damage other nearby systems or parts when removing the transmission assembly.
Installation
1.
To install, reverse the removal procedure.
  
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)
Assemble the DCT (A) to the knock bushing on the engine side (B) and then insert the input shaft to the engine pilot bearing.

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.)
Follow the separated each procedure as below according to reinstallation or replacing with a new dual clutch transmission.
In case of the reinstallation
1.
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 (09453-3L240, 09231-H1100).
2.
After installing the DCT, check the oil level after refilling the DCT with oil.
(Refer to DCT (Dual Clutch Transmission) System - "Transmission Gear Oil")
3.
Clear the diagnostic trouble codes (DTC) using the diagnostic tool. Even though disconnecting the battery negative terminal, the DTCs will not be cleared. So, be sure to clear the DTCs using the diagnostic tool.
In case of the replacing with a new dual clutch transmission.
1.
After replacing the new DCT, it need not oil refill & level check procedure because oil is already filled with specified quantity inside new DCT.
2.
Clear the diagnostic trouble codes (DTC) using the diagnostic tool. Even though disconnecting the battery negative terminal, the DTCs will not be cleared. So, be sure to clear the DTCs using the diagnostic tool.
3.
Perform clutch characteristics input procedure using the diagnostic tool. (One of two procedure must be performed.)
1)
Clutch touch point learning.

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