Hyundai Sonata: Dual Clutch System / Clutch Engagement Fork and Engagement Bearing Repair procedures

Removal

1.	Remove the dual clutch transmission from the vehicle. (Refer to DCT System - "DCT)

2.	Remove the dual clutch assembly. (Refer to Dual Clutch System - "Dual Clutch Assembly")

3.	Remove the clutch engagement bearing 1 (A) and 2 (B).

4.	Remove the clutch engagement fork (A) and engagement bearing sleeve (B).

Installation

•

Apply coat of grease when installing the clutch fork.

Spec grease: CASMOLY 9508

Amount: 0.2g

Install the clutch engagement fork (A) and engagement bearing sleeve (B).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

•	Check dowel pins (A-2ea) when installing the fork assembly. Replace the dowel pin with new part if it is damaged or deformed.

•	Take caution of the direction of fork assembly shaft when installing.

Install the engagement bearing 1 (A).

•	Align the fork with the bearing plastic guide direction.

Install the engagement bearing 2 (A).

•	Take caution and make sure that the bearing plastic stopper (B) is settled in the sleeve (C).

•	Apply coat of spec grease on the 1st input shaft spline (A) after installing the bearing.

•

Apply proper amount of transmission oil on the 2nd input shaft spline (B).

(Be careful not to get oil on the spline when applying coat of oil.)

Spec grease: CASMOLY 9508

Amount: 0.15 ~ 0.25g

Components 1. Clutch housing2. Engagement bearing 2 (Even)3. Egnagement bearing 1 (Odd)4. Engagement bearing sleeve5. Clutch engagement fork ...

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