DCT (Dual Clutch Transmission) System
In this manual: DCT (Dual Clutch Transmission) System
~6min read
8special tools
Service Data
Service Data
Dual Clutch Transmission
| Transmission Model | D7UF1 | |
| Engineering Model | Gamma 1.6 T-GDi | |
| Clutch Type | Dry Dual Plate | |
| Gear ratio | 1st | 3,929 |
| 2nd | 2,318 | |
| 3rd | 2.043 | |
| 4th | 1.070 | |
| 5th | 0,822 | |
| 6th | 0,884 | |
| 7th | 0,721 | |
| Provide Regression | 5.304 | |
| Final gear ratio | 1st / 2nd / 4th / 5th | 4.294 |
| 3rd / 6th / 7th / Reverse | 3.174 | |
Clutch Actuator
| Item | Specification | |
| Resistance (between lines) | Motor 1 | 60 mOhm ± 10% |
| Motor 2 | 64 mOhm ± 10% | |
| Rated Voltage | 12 V | |
| Max. Current | 60 A | |
| Operating Conditions | -40 to 257 °F (-40 to 125 °C) | |
Gear Drive
| Item | Specification | |
| Resistance (between lines) | Shift Motor 1/2 | 135.4 mΩ ± 10 % |
| Select Solenoid 1/2 | 0.7 mΩ ± 10 % | |
| Max. Current | Shift Motor 1/2 | 45 A |
| Select Solenoid 1/2 | 20 A | |
| Select Solenoid Sensor Output | Push | 4.0 ± 0.15 V |
| Pull | 1.0 ± 0.15 V | |
| Operating Conditions | -40 to 257 °F (-40 to 125 °C) | |
| Rated Voltage | 13 V | |
| Sensor Supply Voltage | 8.75 V ± 10% | |
Inhibitor Switch
| Item | Specification |
| Power Supply | 12 V |
| Output type | Output signal combination |
Input Speed Sensor 1/2
| Item | Specification |
| Type | Hall Effect Sensor |
| Operating Conditions | -40 to 302 °F (-40 to 150 °C) |
| Output Signal | High: 11.8–16.8 mA |
| Low: 5.9–8.4 mA |
Tightening Torque
Tightening torque
| Item | N·m | kgf·m | lbf·ft |
| Clutch Release Bearing | 9,8 - 11,8 | 1,0 - 1,2 | 7,2 - 8,7 |
| Clutch Actuator Motor Mounting Bolt | 3,9 - 5,9 | 0,4 - 0,6 | 2,9 - 4,3 |
| Clutch Actuator Mounting Bolt | 19,6 - 26,5 | 2,0 - 2,7 | 14,5 - 19,5 |
| Fork Cover Mounting Bolt | 3,9 - 5,9 | 0,4 - 0,6 | 2,9 - 4,3 |
| Gear Actuator Mounting Bolt | 19,6 - 26,5 | 2,0 - 2,7 | 14,5 - 19,5 |
| 9,8 - 11,8 | 1,0 - 1,2 | 7,2 - 8,7 | |
| Input speed sensor bolt | 9,8 - 11,8 | 1,0 - 1,2 | 7,2 - 8,7 |
| Park/neutral position switch bolt | 9,8 - 11,8 | 1,0 - 1,2 | 7,2 - 8,7 |
| Manual Lever Mounting Nut | 17,4 - 24,5 | 1,8 - 2,5 | 13,0 - 18,1 |
| Oil Drain Plug | 58,8 - 78,5 | 6,0 - 8,0 | 43,4 - 57,9 |
| Oil Filler Plug | 58,8 - 78,5 | 6,0 - 8,0 | 43,4 - 57,9 |
| Shift cable bracket bolt | 19,6 - 26,5 | 2,0 - 2,7 | 14,5 - 19,5 |
| Shift Cable Mounting Nut | 9,8 - 14,7 | 1,0 - 1,5 | 7,2 - 10,8 |
| Shift Cable Bracket Mounting Nut | 9,8 - 14,7 | 1,0 - 1,5 | 7,2 - 10,8 |
| Shift Lever Assembly Mounting Bolt | 8,8 - 13,7 | 0,9 - 1,4 | 9,4 - 10,8 |
| Starter motor bolt | 49,0 - 63,7 | 5,0 - 6,5 | 36,2 - 47,0 |
| Transmission Support Bracket Mounting Bolt | 98,1 - 117,7 | 10,0 - 12,0 | 72,3 - 86,8 |
| Transmission Support Bracket Bolt | 58,9 - 78,5 | 6,0 - 8,0 | 43,4 - 57,8 |
| Transaxle Upper Mounting Bolt (Transaxle to Engine) | 42,2 - 53,9 | 4,3 - 5,5 | 31,1 - 39,8 |
| Transaxle Lower Mounting Bolt (Engine to Transaxle) | 42,2 - 48,1 | 4,3 - 4,9 | 31,1 - 35,4 |
| 42,2 - 53,9 | 4,3 - 5,5 | 31,1 - 39,8 | |
| TCM Bracket Mounting Nut | 9,8 - 11,8 | 1,0 - 1,2 | 7,2 - 8,7 |
Special Service Tools
Special Service Tools
| Tool Name/Number | Illustration | Description |
| Engine mount bracket (beam) 09200-3N000 |
 |
Used to support the engine assembly when removing/installing the transaxle. Used with the support (09200-2S000) and adapter (09200-4X000) ※Refer to the engine mount bracket illustration below. |
| Engine Support Bracket (Stand) A: 09200-2S000 B: 09200-2C100 C: 09200-2C200 |
 |
Used to support the engine assembly when removing/installing the transaxle. Used with the bar (09200-3N000) and adapter (09200-4X000) ※Refer to the engine mount bracket illustration below. |
| Engine Mount Support (Adapter) 09200-4X000 |
 |
Used to support the engine assembly when removing/installing the transaxle. Used with the bar (09200-3N000) and support (09200-2S000) ※Refer to the engine mount bracket illustration below. |
| Oil Seal Installer 09430-C1190 |
 |
Installs the transaxle case oil seal. Used with the handle (09231-H1100) |
| Handle 09231-H1100 |
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Installs the transaxle case oil seal. Used with the installer (09430-C1190) |
| Inhibitor Switch Alignment Pin 09480-A3800 |
 |
Used to hold the "N" range position when installing the inhibitor switch. |
| Dual Clutch Puller 09430-C1180 |
 |
Used to remove the dual clutch assembly. |
| Dual Clutch Installer 09430-2A240 |
 |
Used to install the dual clutch assembly. |
| Clutch Actuator Puller 09430-A5100 |
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Used to remove the clutch actuator assembly. |
| Clutch Actuator Adjuster 09430-C1300 |
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Used to adjust the clutch actuator. Used with the clutch actuator adjusting tool (09430-C1302) |
| Clutch Actuator Adjusting Tool 09430-C1302 |
 |
Used to adjust the clutch actuator. Used with the clutch actuator adjuster (09430-C1300) |
※ Assembly drawing of the special service tool for engine mount
Troubleshooting
Troubleshooting
| Symptom of Malfunction | Probable Cause | Remedy |
| "E" Warning Lamp Illuminated (Vehicle can only be driven in 1st/R gear) |
DCT Learning Not Performed | Perform the DCT manual learning procedure. |
| Driving in odd gears is not possible | Clutch Actuator (Clutch Motor 1 or Position Sensor 1 Malfunction) | Replace the clutch actuator assembly. |
| Gear Actuator (Shift Motor 1, Position Sensor 1, Select Solenoid 1, or Position Sensor 1 Malfunction) | Replace the gear actuator assembly. | |
| Input Speed Sensor 1 Malfunction | Replace the input speed sensor. | |
| Malfunctioning Gears (1, 3, 5, 7) | Replace the gear. | |
| Faulty clutch 1 | Replace the dual clutch assembly. | |
| Faulty clutch release bearing 1 | Replace the clutch release bearing. | |
| Unable to drive in even gears | Clutch Actuator (Clutch Motor 2 or Position Sensor 2 Malfunction) | Replace the clutch actuator assembly. |
| Gear Actuator (Shift Motor 2, Position Sensor 2, Select Solenoid 2, or Position Sensor 2 Malfunction) | Replace the gear actuator assembly. | |
| Input Speed Sensor 2 Malfunction | Replace the input speed sensor. | |
| Malfunctioning Gears (2, 4, 5, 6, R) | Replace the gear. | |
| Faulty clutch 2 | Replace the dual clutch assembly. | |
| Clutch Release Bearing 2 Malfunction | Replace the clutch release bearing. | |
| Driving not possible | Faulty TCM | Replace the TCM. |
| Simultaneous Failure of Odd and Even Systems | Replace the dual clutch assembly or the gear. | |
| Simultaneous Failure of Lock Switch and Shift Lever Sensor | Replace the inhibitor switch. | |
| Manual Mode Disabled | Faulty lock switch | Replace the inhibitor switch. |
| Malfunctioning Shift Lever Sensor | Replace the shift lever. | |
| Faulty manual mode switch | Replace the manual mode switch housing. | |
| Noise | Oil level (low) | Refill the transaxle with oil after inspecting the components (oil, seal, drain plug, and filler plug). |
| Oil (Incorrect Type) | Replace the oil. | |
| Synchronizer ring (worn or damaged) | Replace the synchronizer ring. | |
| Gear (worn or damaged) | Replace the gear. | |
| Bearing (worn or damaged) | Replace the bearing. | |
| Oil leak | Oil level (high) | Check the oil level. |
| Gasket (damaged) | Replace the gasket. | |
| Oil seal (worn or damaged) | Replace the oil seal. | |
| Hard shifting or unable to shift | Oil (Incorrect Type) | Replace the oil. |
| Shift fork (worn) | Replace the shift fork. | |
| Synchronizer ring (worn or damaged) | Replace the synchronizer ring. | |
| Gear (worn or damaged) | Replace the gear. | |
| Hub sleeve (worn or damaged) | Replace the hub sleeve. |
Test yourself
A quick Kia Forte BD quiz: every answer comes with an explanation and a link to the manual page.
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