Hyundai Sonata LF: DCT (Dual Clutch Transmission) System / Dual Clutch System

Hyundai Sonata LF 2014-2019 Service Manual / DCT (Dual Clutch Transmission) System / Dual Clutch System

Description and Operation

Description

•	Components location : DCT (Dual Clutch Transmission)

•

Function

The dual clutch is installed within the transmission.

The dual clutch comprises an odd clutch and an even clutch. The odd clutch transfers and cuts off engine power to the transmission when shifting odd gears.

The even clutch transfers and cuts off engine power to the transmission when shifting even gears.

Dual Clutch Assembly Components and Components Location

Components

1. Retaining ring
2. Spline hub

3. Snap ring
4. Dual clutch assembly

Dual Clutch Assembly Repair procedures

Removal

1.	Remove the dual clutch transmission from the vehicle. (Refer to Dual Clutch System - "Repair procedures")

2.	Remove the retaining (A) and then removing the spline hub (B).

3.	Remove the snap ring (A).

4.	Remove the dual clutch assembly (A) by using the special service tool [SST No.: 09430-C1180].

Installation

•	Check the applied state of grease on input shaft spline part (A) before installing the dual clutch assembly. If there is no grease on input shaft spline part, should apply the grease on each spline end to 10mm.

•	If excessively applied grease, grease can be scattered by centrifugal force which can contaminate the clutch disc. This can cause a loss of friction force

Specified grease: Extreme pressure grease for vehicle

Quantity: 0.15 ~0.25 g

1.	Install the SST (No.:09430-2A240) on the support bearing within the dual clutch assembly (A).

2.	Install the SST (No. : 09430-2A240) on the clutch housing side.

3.	Install the dual clutch assembly (A) using the SST (No. : 09430-2A240).

4.	Install the snap ring (A).

5.	Install the spline hub (B) and the install the snap ring (A).

6.	Perform the work procedures for abrasion compensation reset after installing the new dual clutch assembly. (Refer to Clutch Actuator Assembly - "Adjustment")

7.	Perform the clutch touch point learning procedure using the GDS after replacing the dual clutch assembly.

Clutch Engagement Fork and Engagement Bearing Components and Components Location

Components

1. Clutch housing
2. Engagement bearing 2 (Even)
3. Egnagement bearing 1 (Odd)

4. Engagement bearing sleeve
5. Clutch engagement fork

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

Shift Cable Repair procedures

Removal 1. Remove the air cleaner assembly and air duct. (Refer to Engine Mechnical System - "Air cleaner") 2. Remove the TCM. (Refer to Dual Clutch Transmission Control System - "TCM") 3...

Other information:

Hyundai Sonata LF 2014-2019 Service Manual: Timing Chain Cover Components and Components Location

C..

Hyundai Sonata LF 2014-2019 Service Manual: DCT Control Module (TCM) Schematic Diagrams

1. TCM Connector and Terminal Function 2. TCM Terminal Function Connector [A] PinDescriptionPinDescription1Clutch Actuator (Clutch Motor 1 (ODD)_Phase V)17-2Clutch actuator (Clutch Motor 2 (EVEN) Phase V)18Clutch Actuator (Clutch Motor 1 (ODD)_HALL 1)3Select Actuator (Shift Solenoid 2 (EVEN)_Ground)19Clutch Actuator (Clutch Motor 1 (ODD)_Supply)4Select Actuator (Shift Solenoid 1 (ODD) Push)20Select Actuator (Shift Solenoid 1 (ODD)_Sensor Supply)5Clutch Actuator (Clutch Motor 1 (ODD)_Phase U)21Select Actuator (Shift Solenoid 2 (EVEN)_Sensor Supply)6Clutch Actuator (Clutch Motor 2 (EVEN)_Phase U)22Select Actuator (Shift Solenoid 2 (EVEN)_Sensor Ouput)7Select Actuator (Shift Solenoid 1 (ODD)_Ground)23Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 2)8Select Actuator (Shift Solenoid 2 (EVEN)_ Pull)24Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 3)9Clutch Actuator (Clutch Motor1 (ODD)_Phase W)25Clutch Actuator (Clutch Motor 2 (EVEN)_Ground)10Clutch Actuator (Clutch Motor 2 (EVEN)_Phase W)26Select Actuator (Shift Solenoid 1 (ODD)_Sensor Output)11Select Actuator (Shift Solenoid 1 (ODD) Pull)27-12Select Actuator (Shift Solenoid 2 (EVEN) Push)28Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 1)13Clutch Actuator (Clutch Motor 1 (ODD)_HALL 2)29Clutch Actuator (Clutch Motor 2 (EVEN)_Supply)14Clutch Actuator (Clutch Motor (ODD)_HALL 3)30Select Actuator (Select Solenoid 1 (ODD)_Sensor Ground)15Clutch Actuator (Clutch Motor 1 (ODD)_Ground)31Select Actuator (Select Solenoid 2 (EVEN)_Sensor Ground)16-32- Connector [B] PinDescriptionPinDescription1-35-2-36-3ON / START Input37-4Paddle Shift (Up) Switch signal38-5Inhibitor Switch "P" Input signal39-6Inhibitor Switch "R" Input signal40-7Inhibitor Switch "D" Input signal41Shift Actuator (Shift Motor 2 (EVEN) _HALL 2)8Sports mode "Down" shift42Shift Actuator (Shift Motor 2 (EVEN) _HALL 3)9Clutch Speed Sensor (EVEN) Ground43Inhibitor Switch "M" Input signal10-44CAN1 Communication Port1 High11-45CAN1 Communication Port1 Low12-46-13Shift Actuator (Shift Motor 1 (ODD) _HALL 2)47-14Shift Actuator (Shift Motor 1 (ODD) _HALL 3)48Flex ray High (BP)15-49Input Speed Supply 1 (ODD)16-50Input Speed Signal 1 (ODD)17Battery Power Low VBD 51-18Paddle Shift Down signal52-19Shift Lever Select Switch53-20Inhibitor Switch "N" Input signal54Shift Actuator (Shift Motor 2 (EVEN) _Supply)21Sports mode "Up" shift55Shift Actuator (Shift Motor 2 (EVEN) _HALL 1)22-56Shift Actuator (Shift Motor 2 (EVEN) _Sensor Ground)23Input Speed Supply 2 (EVEN)57Power Ground 1 for High Current Modules245V spare supply output58Power Ground 2 for High Current Modules25-59Shift Actuator (Shift Motor 2 (EVEN)_Phase W)26Shift Solenoid 1 Position Sensor Output60Shift Actuator (Shift Motor 1 (ODD)_Phase W)27Select Actuator (Shift Motor 1 (ODD)_HALL 1)61 Power Ground 3 for High Current Modules28Select Actuator (Shift Motor 1 (ODD)_Sensor Ground)62-29-63Shift Actuator (Shift Motor 2 (EVEN)_Phase V)30CAN2 Communication Port2 High64Shift Actuator (Shift Motor 1 (ODD)_Phase V)31CAN2 Communication Port2 Low65Motor Supply Voltage 1 from Direct Battery32-66Motor Supply Voltage 2 from Direct Battery33-67Shift Actuator (Shift Motor 2 (EVEN)_Phase U)34Flex ray bus, BM68Shift Actuator (Shift Motor 1 (ODD)_Phase U) 3...