Hyundai Sonata LF Quiz
DCT (Dual Clutch Transmission) System

Clutch Actuator Assembly Repair Procedures

In this manual: DCT (Dual Clutch Transmission) System
General Information — 9Engine Mechanical System — 90Engine Electrical System — 58Emission Control System — 24Engine Control System/Fuel System — 114Drive Shaft and Axle — 15Suspension System — 35Steering — 19Restraints — 50Brake System — 54Body (Interior and Exterior) — 213Body Electrical System — 241Heating, Ventilation, and Air Conditioning — 56DCT (Dual Clutch Transmission) System — 52
41steps
~261min
5/5difficulty
3special tools
010203040505.94N·mlb·ft
Tightening torque found on this page
Done 0 of 41

Removal

  1. Remove the air cleaner assembly and air duct. (Refer to Engine Mechanical System - "Air Cleaner")
  2. Remove the TCM. (Refer to Dual Clutch Transmission - "TCM")
  3. Remove the battery and tray. (Refer to Engine Electrical System — "Battery")
  4. Disconnect the clutch actuator connector (A).
  5. Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")
  6. Remove the fork cover after loosening the bolt (A-2ea).

    Tightening torque: 3.9 ~ 5.9 N·m

  7. Remove the vacuum pump (B) by loosening the bracket mounting bolts (A-2ea).
  8. Remove the starter motor mounting bolts (S) and the lower mounting bolt (B).
  9. Secure the clutch release fork by turning the bolt after installing the Special Service Tool (09430-A5100).
  10. Remove the clutch actuator assembly from the transmission after loosening the bolts (A-3ea).

Inspection

  1. Remove the clutch actuator. (Refer to Clutch Actuator Assembly - "Removal")
  2. Install the clutch actuator (A) on the Special Service Tool (09430-C1302) and secure the actuator with the nuts.
  3. Remove the clutch actuator motor (A) and the ground bolt (B).
  4. Insert the Special Service Tool (09430-C1302) into the ball screw and turn counterclockwise until a click is heard.
    • If no click is heard, turn the ball screw counterclockwise until it stops.
    • Be very careful not to keep turning the screw counterclockwise when it is at the end position, as this may cause damage to the actuator.
  5. Measure the length (C) from the base plane (A) to the end of the rod (B).

    C Service Standard: 25 mm (0.9843 in.)

  6. If the rod length is approximately 25 mm (0.9843 in.) less than specified, replace the dual clutch and clutch actuator assembly, and the bearing carrier.

Installation

  1. Install in the reverse order of removal.
    • Perform the procedure to reset the wear compensation before installing the new clutch actuator assembly. (Refer to Clutch Actuator Assembly - "Adjustment")
    • Check the assembled condition of the installation pins (A) before installing the clutch actuator assembly.
    • Perform the clutch touch point learning procedure using GDS after replacing the clutch actuator assembly.

Adjustment
Perform the procedure to reset the wear compensation according to the table below.
Item Specifications
Dual Clutch Assembly Replacement Initialize
Clutch Actuator Assembly Replacement Rewind
Dual Clutch Assembly + Clutch Actuator Assembly Replacement Not required

How to Rewind the Wear Compensation

  1. Remove the clutch actuator assembly. (Refer to Clutch Actuator Assembly - Removal)
  2. Install the faulty clutch actuator (A) on the Special Service Tool (09430-C1302) and secure the actuator with the nuts.
  3. Remove the clutch actuator motor (A) and the ground bolt (B).
  4. Insert the Special Service Tool (09430-C1302) into the ball screw and turn counterclockwise until a click is heard.
    • If no click is heard, turn the ball screw counterclockwise until it stops.
    • Be very careful not to keep turning the screw counterclockwise when it is at the end position, as this may cause damage to the actuator.
  5. Measure the length (C) from the base plane (A) to the end of the rod (B).
  6. Pull the lever (A) until it clicks, then measure the length to check the rod length of the faulty clutch actuator (B).
  7. Remove the clutch actuator from the special service tool (09430-C1302).
  8. Install the new clutch actuator (A) on the Special Service Tool (09430-C1302) and secure the actuator with the nuts.
  9. Remove the clutch actuator motor (A) and the ground bolt (B).
  10. Insert the Special Service Tool (09430-C1302) into the ball screw and turn counterclockwise until a click is heard.
    • If no click is heard, turn the ball screw counterclockwise until it stops.
    • Be very careful not to keep turning the screw counterclockwise when it is at the end position, as this may cause damage to the actuator.
  11. Secure the rod on the hook (B) and remove the rubber boot (A).
  12. Insert the Special Service Tool (09430-C1300) into the rubber seal hole, then adjust the rod length to match the length of the previous clutch actuator rod by turning it clockwise.
  13. Pull the lever (A) until it clicks, then measure the length to check the rod (B).
  14. Install the rubber seal (A).
  15. Install the clutch actuator motor (A) and the ground bolt (B) with the O-ring (C).
    Check the O-rings (C) and install them carefully.

    Tightening torque: 3.9 ~ 5.9 N·m

How to Initialize the Wear Compensation

  1. Remove the clutch actuator assembly. (Refer to Clutch Actuator Assembly - Removal)
  2. Install the clutch actuator (A) on the Special Service Tool (09430-C1302) and secure the actuator with the nuts.
  3. Remove the clutch actuator motor (A).
  4. Insert the Special Service Tool (09430-C1302) into the ball screw and turn counterclockwise until a click is heard.
    • If no click is heard, turn the ball screw counterclockwise until it stops.
    • Be very careful not to keep turning the screw counterclockwise when it is at the end position, as this may cause damage to the actuator.
  5. Tighten the nut (A) after installing the T-plates (B) at 49 mm (1.9291 in.).
  6. Remove the rubber seal (C).
  7. Insert the Special Service Tool (09430-C1300) into the hole of the rubber seal, then move it toward the T-plates (A) by turning clockwise.
  8. Secure the rod to the hook (B) and install the rubber seal (A).
  9. Pull the lever (A) until it clicks, then measure the length again to check that it matches the specified length (B).

    Specified length: 71.5 mm (2.8150 in.)

  10. Install the clutch actuator motor (A) and the weight (B).
    Check the O-rings (C-2ea) and install them carefully.

    Tightening torque: 3.9 ~ 5.9 N·m

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