DCT (Dual Clutch Transmission) Repair Procedures

Removal

1. 1
   Remove the air cleaner assembly and air duct. (Refer to Engine Mechanical System - "Air Cleaner")
2. 2
   Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")
3. 3
   Remove the ECM. (Refer to Engine Control System - "ECM")
4. 4
   Disconnect the connectors shown in the illustration below.

   A.	Inhibitor Switch Connector

   B.	Input Shaft Speed Sensor Connector

   C.	Gear Actuator Solenoid Connector

   D.	Clutch Actuator Connector

   

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

   

6. 6
   Remove the wiring bracket bolt (A-2ea).

   Tightening torque: (A) 9.8–11.7 N·m

   

7. 7
   Remove the nut (A) and shift cable bracket bolt (B-2ea). Tightening torque: (A) 9.8–13.7 N·m (B) 19.6–26 N·m

   

8. 8
   Remove the ground bolt (A).

   Tightening Torque: 9.8–11.8 N·m

   

9. 9
   Remove the upper transmission mounting bolts (A-2ea) and the starter motor bracket bolt (B).

   Tightening torque: 42.1–44 N·m

   

10. 10
    Remove the upper hood cover. (Refer to Body - "Upper Cover Panel")
11. 11
    Assemble the engine support bracket (beam No.: 09200-38001 or 09200-3N000, support No.: 09200-2S000). (Refer to Special Service Tools — "Special Tool for Engine Support Bracket" assembly drawing.)
12. 12
    Using the engine support fixture (A), hold the engine and transmission assembly safely.

    

13. 13
    Remove the dust cover (A).

    

14. 14
    Remove the transmission support bracket bolt (A-2ea).

    Tightening torque: 107.9–128 N·m

    

15. 15
    Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")
16. 16
    Remove the suspension member. (Refer to Suspension System - "Suspension Member")
17. 17
    Remove the front drive shaft. (Refer to Drive Shaft and Axle — "Front Propeller Shaft")
18. 18
    Remove the vacuum pump. (Refer to Brake System — "Vacuum Pump")
19. 19
    Remove the transmission support bracket (A).

    Tightening torque: 58.8–78 N·m

    

20. 20
    Remove the starter motor bolt (A).

    Tightening torque: 42.1–44 N·m

    

21. 21
    Remove the roller rod support bracket (A).

    Tightening Torque: 49.0–69 N·m

    

22. 22
    Remove the intercooler inlet pipe (A).

    Tightening torque: 19.6–26 N·m

    

23. 23
    Remove the transmission lower mounting bolts (A-3ea, B-2ea).

    Tightening torque: 42.2–54 N·m

    

Installation

1. 1
   To install, reverse the removal procedure.
2. 2
   When reinstalling

   1. If the differential seal is damaged and oil leaks, replace the seal with a new one. When installing a new seal, use the special tool. — Transmission side 2WD, clutch housing side: 09430-C1190 — Transmission side 4WD, clutch housing side: 09431-39000 — Driven gear seal (for 4WD vehicles): 09473-D3500
   2. After installing the DCT, check the oil level after refilling the DCT with oil. (Refer to Transaxle Oil - Repair Procedures)
   3. Erase the Diagnostic Trouble Codes (DTCs) using GDS. Even if the negative battery terminal is disconnected, the DTCs will not be erased. Therefore, be sure to clear the DTCs using GDS.
3. 3
   When replacing with a new dual clutch transmission.

   1. After replacing with a new DCT, it is not necessary to refill or check the oil level, as the specified amount of oil is already filled inside the new DCT.
   2. Erase the Diagnostic Trouble Codes (DTCs) using GDS. Even if the negative battery terminal is disconnected, the DTCs will not be erased. Therefore, be sure to clear the DTCs using GDS.
   3. Perform the clutch characteristics input procedure using GDS. (Either of the two procedures must be performed.)

   • Clutch Characteristics Input (Manual Learning)

     

   • Clutch Touch Point Learning