Kia Forte: DCT(Dual Clutch Transmission) System / DCT(Dual Clutch Transmission)
Components and components location

1. DCT (Dual Clutch Transmission)
assembly
2. Clutch actuator assembly
3. Gear actuator assembly
4. Roll rod support bracket
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5. DCT support bracket
6. Roll rod bracket
7. Dust cover
8. Support bracket mounting bolt
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External Damper Checking Method
& Assemble avoidance of wear point03:43
1. |
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechanical System - "Air cleaner")
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2. |
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
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3. |
Disconnect the connectors (A, B ,C ,D) in the illustration below.
A. |
Inhibitor switch connector
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B. |
Input shaft speed sensor connector
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C. |
Gear actuator solenoid connector
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D. |
Clutch actuator connector
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4. |
Disconnect the gear actuator motor connector (A).

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5. |
Remove the wiring bracket mounting bolts (A).
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
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6. |
Remove the shift cable after loosening the bolts (A) and nut (B).
Tightening torque :
(A) 9.8 - 14.7 N·m (1.0 - 1.5 kgf·m, 7.2 - 10.8 lb·ft)
(B) 19.6 - 26.5 N·m (2.0 - 2.7 kgf·m, 14.5 - 19.5 lb·ft)
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7. |
Loosen the ground bolt (A).
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
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8. |
Loosen the transmission upper mounting bolts (A) and starter mounting
bolts (B).
Tightening torque :
(A) : 42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)
(B) : 49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)
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9. |
Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
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10. |
Assemble the engine support fixture on the engine room.
(Refer to Special Service Tools - "Engine support fixture assembly drawing")
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11. |
Using the engine support fixture, hold the engine and transaxle assembly
safely.

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12. |
Support the transaxle safely on a jack.

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13. |
Remove the dust cover (A).

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14. |
Loosen the transmission mounting bracket bolts (A).
Tightening torque :
98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb·ft)
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15. |
Remove the transmission support bracket (A).
Tightening torque :
58.8 - 78.5 N·m (6.0 - 8.0 kgf·m, 43.4 - 57.9 lb·ft)
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16. |
Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
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17. |
Remove the clips (A) from wiring bracket.

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18. |
Remove the sub frame.
(Refer to Suspension System - "Sub Frame")
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19. |
Remove the drive shaft assembly.
(Refer to Driveshaft and Axle - "Front Driveshaft")
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20. |
Remove the vacuum pump.
(Refer to Brake System - "Vacuum Pump")
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21. |
Remove the intercooler inlet hose & pipe (A).
Tightening torque :
18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)
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22. |
Remove the roll rod support bracket (A).
Tightening torque :
49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.2 - 50.6 lb·ft)
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23. |
Support the transmission safely by using the jack.
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24. |
Loosen the transmission lower mounting bolts (A, B).
Tightening torque :
(A) : 42.2 - 48.1 N·m (4.3 - 4.9 kgf·m, 31.1 - 35.4 lb·ft)
(B) : 42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)
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25. |
After separating the transmission from the engine, remove the transmission
by lowering the jack slowly.
Be careful not to damage other nearby systems or parts when removing
the transmission assembly.
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26. |
Remove the dual clutch assembly from the transmission.
(Refer to Dual Clutch System - "Dual Clutch Assembly")
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1. |
Install in the reverse order of removal.
•
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If dual clutch assembly or clutch actuator assembly needs
replacement, perform the work procedures for clutch wear
reset by referring to the table below.
Replacement part
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Remedy
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Dual clutch assembly
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Initialize
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Clutch actuator assembly
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Rewind
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Dual clutch assembly + Clutch actuator assembly
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Not required
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1) |
Remove the fork cover (A).

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2) |
Remove the clutch actuator assembly (A).

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3) |
Perform the clutch wear compensation reset.
(Refer to Dual Clutch Transmission Control System - "Clutch
Actuator Assembly")
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4) |
Install the the clutch actuator assembly (A).
Tightening torque :
19.6 - 26.5 N·m (2.0 - 2.7 kgf·m, 14.5 - 19.5
lb·ft)
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5) |
Install the fork cover (A).
Tightening torque :
3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft)
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Matters that require attention when installing the dual clutch
transmission (DCT) to engine
(Refer to the video clip)
1) |
Check the pilot bearing (B) and external damper (A) on
the side of engine for any dents, damages and deformations
before installing the DCT.

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2) |
Align the external damper spline (A) with the dual clutch
spline (B).

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3) |
Insert the input shaft (A) into the engine pilot bearing
(B) and then assemble the DCT to the knock bushing on the
engine side.

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4) |
After mounting the DCT to the engine by pushing the DCT,
tighten the mounting bolts making sure that there is no
gap (less than 2 mm) between the clutch housing and the
engine block.
(If the bolt is tightened while there is a gap, then
the spline of external damper or clutch will be damaged
or broken.)
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2. |
Observe each separate procedure below for reinstallation or replacement
with a new dual clutch transmission.
When reinstalling
1) |
If the differential oil seal is damaged and oil is leaking, replace
the oil seal with a new one. When installing a new oil seal, use
the special tool (09430-C1190, 09231-H1100).
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2) |
After installing the DCT, check the oil level after refilling
the DCT with oil.
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3) |
Clear the diagnostic trouble codes (DTC) using the KDS. Disconnecting
the battery negative terminal will not clear the DTCs. Clear the
DTCs using the KDS at all times.
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When replacing with a new dual clutch transmission
1) |
After replacing the new DCT, it need not oil refill & level check
procedure because oil is already filled with specified quantity
inside new DCT.
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2) |
Clear the diagnostic trouble codes (DTC) using the KDS. Disconnecting
the battery negative terminal will not clear the DTCs. Clear the
DTCs using the KDS at all times.
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3) |
Perform clutch characteristics input procedure using the KDS.
(One of two procedures must be performed.)
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• |
Clutch characteristics input (Manual Teaching)

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• |
Clutch touch point learning

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Repair procedures
Inspection
Oil level check
1.
Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
2.
...
Other information:
The fuel gauge indicates the approximate
amount of fuel remaining in the
fuel tank. The fuel tank capacity is
indicated in Chapter 8. The fuel
gauge is supplemented by a low fuel
warning light, which will illuminate
when the fuel tank is nearly empty.
On inclines or curves, the fuel g ...
Components and components location
Components
1. Right remote control switch
(Trip Computer + SCC)
Schematic diagrams
Circuit Diagram
[Trip + SCC]
Repair procedures
Removal and Installation
1.
...