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 TCM. (Refer to Dual Clutch Transmission Control System - "TCM").
3. 3
   Remove the battery and tray. (Refer to Engine Electrical System — "Battery")
4. 4
   Disconnect the connectors shown in the figure below. (A) Lock Switch Connector (B) Clutch Actuator Connector (C) Gear Shift Actuator Solenoid Connector (D) Input Shaft Speed Sensor Connector

   

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

   

6. 6
   Remove the ground (A) and wiring bracket (B-2ea) after removing the bolts.

   

7. 7
   Remove the control cable (B) after removing the nut (A).

   

8. 8
   Remove the ground strap (A) after removing the bolts.

   

9. 9
   Loosen the upper transmission mount bolts (A-2ea) and the starter mounting bolt (B-1ea). Tightening torque (A), (B): 42.2 ~ 54 N·m

   

10. 10
    Assemble the engine mount support (beam number: 09200-38001 or 09200-3N000, support No.: 09200-2S000). (Refer to Special Service Tools - "Engine Mount Support Assembly Drawing")
11. 11
    Using the engine support, securely hold the engine and transaxle assembly.

    

12. 12
    Remove the DCT mounting bracket cover (A).

    

13. 13
    Remove the DCT support bracket bolts (A).

    Tightening torque: 88.3 ~ 108 N·m

    

14. 14
    Remove the DCT support bracket (A).

    Tightening Torque: 58.8 ~ 78 N·m

    

15. 15
    Remove the under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover")
16. 16
    Remove the front drive shaft. (Refer to Drive Shaft and Axle - "Drive Shaft Assembly")
17. 17
    Remove the suspension member. (Refer to Suspension System - "Suspension Member")
18. 18
    Loosen the intercooler inlet pipe mounting bolts (A-2ea).

    Tightening torque: 19.6 - 26 N·m

    

19. 19
    Separate the vacuum pump (A) from the transmission by loosening the bolts (B-2ea).

    Tightening torque: 19.6 - 29 N·m

    

20. 20
    Loosen the starter mounting bolt (A).

    Tightening torque: 42.2 ~ 54 N·m

    

21. 21
    Safely support the transmission with a jack.
22. 22
    Loosen the lower transmission mount bolts (A-5ea).

    Tightening torque: 42.2 ~ 54 N·m

    

23. 23
    After separating the transaxle from the engine, remove the transaxle by slowly lowering the jack.

    Be careful not to damage other systems or nearby parts when removing the transmission assembly.

Installation

1. 1
   Install in the reverse order of removal.

   Precautions for Installing the Dual Clutch Transmission (DCT) on the Engine Inspect the guide bearing (B) and external damper (A) on the engine side for dents, damage and deformation before installing the DCT. Align the splines of the outer damper (A) with the splines of the dual clutch (B). Insert the input shaft (A) into the engine guide bearing (B), then install the DCT on the dowel sleeve on the engine side. After attaching the DCT to the engine, press the DCT and tighten the mounting bolts, making sure there is no gap (less than 2 mm) between the clutch housing and the cylinder block. (If the bolts are tightened with a gap present, the splines of the outer damper or coupling may be damaged or broken.)

2. 2
   Perform the separate procedures below when reinstalling or replacing the dual clutch transmission with a new one. When reinstalling

   A.	If the differential seal is damaged and oil is leaking, replace the seal with a new one. When installing the new seal, use the special tools (9430-C1190, 09231-H1100).

   B.	After installing the DCT, check the oil level after refilling the DCT with oil.

   C.	Erase the diagnostic trouble codes (DTCs) using GDS. Even if the negative battery terminal is disconnected, DTCs will not be cleared. Therefore, be sure to clear the DTCs using GDS.

3. 3
   When replacing with a new dual clutch transmission.

   A.	After replacing with a new DCT, the oil level check procedure is not required because the correct amount of oil is already filled inside the new DCT.

   B.	Erase the diagnostic trouble codes (DTCs) using GDS. Even if the negative battery terminal is disconnected, DTCs will not be cleared. Therefore, be sure to clear the DTCs using GDS.

   C.	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