Kia Stonic Quiz
DCT (Dual Clutch Transmission) System

DCT (Dual Clutch Transmission) System

In this manual: DCT (Dual Clutch Transmission) System
General Information — 8Maintenance — 31Engine Mechanical — 49Engine Electrical — 15Emission control system — 11Engine Control System/Fuel System — 45Clutch System — 12Manual Transaxle System — 11DCT (Dual Clutch Transmission) System — 16Drive Shafts and Axles — 9Suspension — 16Steering — 10restraint system — 15Braking system — 22Body (Interior and Exterior) — 89Rear Seat — 16Electrical System — 25Electrochromic Interior Rear View Mirror — 64Heating, Ventilation, and Air Conditioning — 31
31steps
~201min
5/5difficulty
3special tools
0102030405026.520N·mlb·ft
Tightening torque found on this page
Done 0 of 31

Components and Components Location

COMPONENTS LOCATION

1. DCT (Dual Clutch Transmission)
2. Clutch actuator
3. Transmission actuator
4. Transmission support bearing retainer		 5. DCT support bracket
6. Crossmember clamp
7. Dust cover
8. Support bracket mounting bolt

repair procedures

expansion

  1. Remove the air cleaner assembly.

    (Refer to Engine Mechanical — Air Cleaner)

  2. Remove the battery and battery tray from the vehicle.

    (Refer to Group EE — Battery)

  3. Disconnect the interlock switch connector (A) and the input shaft speed sensor connector (B).

  4. Disconnect the wiring harness from the bracket (C).

  5. Disconnect the connectors (A, B, C) shown in the illustration below.

    (A) Transmission actuator connector

    (B) Transmission actuator solenoid connector

    (C) Clutch actuator connector

  6. Disconnect the shift cable (C) by removing the nut (A) and bolt (B).

    Tightening torque: (A): 9.8–14.7 N·m (1.0–1.5 kgf·m) (B): 19.6–26 N·m

  7. Transmission upper mounting bolt (A) and starter mounting bolt (B).

    Tightening torque: (A) 42.2~54 N·m (B) 49.0~64 N·m

8th.

Install the engine mount in the engine compartment.

  1. Remove the hood upper panel.

    (Refer to Body — Hood Upper Trim)

  2. Loosen the engine wiring harness mounting screws (A).

  3. Remove the oil level gauge (A).

  4. Install the engine support (09221-A3100).

  5. Install the engine support bracket in the engine compartment.

    (Refer to Special Service Tools - "Engine Support Fixture Drawing")

  6. Use the engine support bracket to support the engine and transaxle.

  1. Securely support the transaxle with a floor jack.

  2. Remove the fender apron (A).

  3. Loosen the transaxle bracket mounting bolts (A).

    Tightening torque: 107.9~128 N·m

  4. Remove the transmission support bracket (A).

    Tightening torque: 58.8~78 N·m

  5. Remove the under cover.

    (Refer to Engine Mechanical - "Engine Under Cover")

  6. Remove the subframe.

    (Refer to Suspension - "Subframe")

  7. Remove the driveshaft.

    (Refer to Drive Shaft and Axle - "Front Drive Shaft")

  8. Loosen the ground bolt (A) and the cable holder mounting bolt (B).

    Tightening torque: 19.6~26 N·m

  9. Remove the exhaust manifold bracket (A).

    Tightening torque: 39.2~49 N·m

  10. Loosen the intercooler inlet pipe mounting bolts (A).

    Tightening torque: 18.6~24 N·m

  11. Remove the transaxle support bearing holder (A).

    Tightening torque: 49.0~69 N·m

  12. Securely support the transaxle with a floor jack.

  13. Remove the starter motor mounting bolt (A).

    Tightening torque: 49.0~64 N·m

  14. Loosen the lower transaxle mounting bolts (A, B).

    Tightening torque: (A) 48.1–54 N·m (B) 42.2–44 N·m

  15. After separating the engine from the transaxle, slowly lower the transaxle using the floor jack.

  16. Remove the dual clutch from the transaxle.

    (Refer to Dual Clutch - "Dual Clutch")

Installation

  1. Installation is the reverse of removal.

  2. Perform the various reassembly or replacement operations described below with a new dual clutch transmission.

    When Reinstalling

    1. If the differential oil seal is damaged and oil is leaking, replace the oil seal with a new one. Remove the oil seal using the special service tools (09431-39000, 09231-H1100).

    2. After installing the DCT, refill the DCT fluid and check the fluid level.

    3. Erase the diagnostic trouble codes (DTC) using the KDS. Disconnecting the negative battery terminal does not guarantee erasure of the DTCs. Always erase DTCs using the KDS.

    When Replacing with a New Dual Clutch Transmission

    1. After installing a new DCT, it is not necessary to refill the fluid, and the fluid level also does not need to be checked, since the new DCT is already filled with the specified amount of fluid.

    2. Erase the diagnostic trouble codes (DTC) using the KDS. Disconnecting the negative battery terminal does not guarantee erasure of the DTCs. Always erase DTCs using the KDS.

    3. Perform the clutch input signal characteristic learning procedure using the KDS. (One of the two procedures must be performed.)

    • Clutch input signal characteristic learning (manual programming)

    • Clutch kiss point programming

Test yourself

A quick Kia Stonic quiz: every answer comes with an explanation and a link to the manual page.