Hyundai Tucson: Dual clutch assembly

Components

1. Dual clutch assembly
2.  Snap ring
3. Spline hub
4. Retaining ring

Removal

1. Remove the dual clutch transmission from the vehicle.

(Refer to Dual Clutch Transmission Assembly - "DCT (Dual Clutch Transmission)")

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

3. Remove the snap ring (A).

WARNING

• The snap ring can deform when it removed by forced removal and can't reuse it.
• If it's difficult to remove the snap ring for stuck, release the stuck by using a rubber hammer with a center cylinder of dual clutch installer (09430-2A240) and then remove the snap ring.
• Be careful to damage dual clutch assembly support bearing rubber seal.

WARNING

 l)When removing is not possible due to snap ring jamming, place the center cylinder (09430-2A240) and hit it with a rubber hammer. When it looses, remove it.

2)In case of the dual clutch reuse, make sure not to damage the dual clutch support bearing rubber seal (A) when removing the snap ring.

4. Remove the dual clutch assembly (A).

1)Attach the special tool (09430-C1180) to the dual clutch assembly and remove it with a wrench or a spanner.

2)Use a special tool (09430-C 1180) to detach the dual clutch from the transmission housing.

* When detaching the dual clutch from the transmission housing, make sure not to drop the dual clutch.

Installation

WARNING

1. Remove the dust and foreign matters from the input shaft spline (A) and shaft (B).

* Do not use steel soles and sandpapers. WD40 and anti-corrosive lubricant. (It could cause a corrosion of the rubber or oil seals.)

2)Check the grease on the input shaft spline part (A). If there is no grease, apply it to the 10mm point from the each end of the spline.

* Grease overspraying may result excessive scattering and this may cause the clutch to slip.

Specified grease : Extreme pressure grease for vehicle

Quantity : 0.15 - 0.25g

1. Fix the special tool (09430-C 1180) to the dual clutch assembly at three places at 120-degree intervals, then move to the top of the housing.

2. Assemble the dual clutch to the input shaft 2 temporarily.

WARNING

Dual clutch temporary assembly condition

3. In the input shaft 2. the center bearing inner ring should be properly and temporarily inserted.
4. When th clutch is press-fitted in an unstable temporary assembly, it may cause damage to the clutch.
5. Install the SST (No.:09430-2A240) on the support bearing within the dual clutch assembly (A).

4. Install the SST (No. : 09430-2A240) on the clutch housing side.
5. Install the dual clutch assembly (A) using the SST (No. : 09430-2A240).

6. Install the snap ring (A).

WARNING

After tightening the snap ring (A), see if it can properly rotates to the right or the left.

7. Install the spline hub (B) and the install the retaining ring (A).

8. Install the dual clutch transmission in the vehicle.

(Refer to Dual Clutch Transmission Assembly - "DCT (Dual Clutch Transmission)")

9. Perform the work procedures for abrasion compensation reset after installing the new dual clutch assembly.

(Refer to Clutch Actuator & TCM Assembly - "Adjustment")

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

WARNING

• Even if you removed and reinstalled the clutch actuator, be sure to perform the touch point learning.
• If you have replaced the dual clutch assembly or clutch actuator, be sure to perform the touch point learning.

READ NEXT: