Kia Forte: DCT(Dual Clutch Transmission) System

Kia Forte 2019-2020 (BD) Service Manual / DCT(Dual Clutch Transmission) System

Service data
Service Data

Dual clutch transmission

Transmission model
D7UF1
Engine model
Gamma 1.6 T-GDI
Clutch Type
Dry dual plate
Gear ratio
1st
3.929
2nd
2.318
3rd
2.043
4th
1.070
5th
0.822
6th
0.884
7th
0.721
Reverse
5.304
Final gear ratio
1st / 2nd / 4th / 5th
4.294
3rd / 6th / 7th / Reverse
3.174

Clutch actuator

Item
Specification
Resistance (line to line)
Motor 1
60 mΩ ± 10 %
Motor 2
64 mΩ ± 10 %
Rated voltage
12 V
Max. current
60 A
Operation condition
-40 to 257°F (-40 to 125°C)

Gear actuator

Item
Specification
Resistance (line to line)
Shift motor 1/2
135.4 mΩ ± 10 %
Select solenoid 1/2
0.7 mΩ ± 10 %
Max. current
Shift motor 1/2
45 A
Select solenoid 1/2
20 A
Select solenoid sensor output
Push
4.0 ± 0.15 V
Pull
1.0 ± 0.15 V
Operation condition
-40 to 257°F (- 40 to 125°C)
Rated voltage
13 V
Sensor supply voltage
8.75 V ± 10 %

Inhibitor Switch

Item
Specification
Power supply
12 V
Output type
Combination of output signals

Input speed sensor 1/2

Item
Specification
Type
Hall effect sensor
Operation condition
-40 to 302°F (-40 to 150°C)
Output signal
High: 11.8 - 16.8 mA
Low: 5.9 - 8.4 mA

Tightening torque
Tightening Torques

Item
N·m
kgf·m
lb·ft
Clutch engagement bearing
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Clutch actuator motor mounting bolt
3.9 - 5.9
0.4 - 0.6
2.9 - 4.3
Clutch actuator mounting bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5
Fork-cover-mounting-bolt
3.9 - 5.9
0.4 - 0.6
2.9 - 4.3
Gear actuator mounting bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Input shaft speed sensor mounting bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Inhibitor swtich mounting bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Manual lever mounting nut
17.4 - 24.5
1.8 - 2.5
13.0 - 18.1
Oil drain plug
58.8 - 78.5
6.0 - 8.0
43.4 - 57.9
Oil filler plug
58.8 - 78.5
6.0 - 8.0
43.4 - 57.9
Shift cable bracket mounting bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5
Shift cable mounting nut
9.8 - 14.7
1.0 - 1.5
7.2 - 10.8
Shift cable retainer mounting nut
9.8 - 14.7
1.0 - 1.5
7.2 - 10.8
Shift lever assembly mounting bolt
8.8 - 13.7
0.9 - 1.4
9.4 - 10.8
Stater motor mounting bolt
49.0 - 63.7
5.0 - 6.5
36.2 - 47.0
Transmission support bracket mounting bolt
98.1 - 117.7
10.0 - 12.0
72.3 - 86.8
Transmission support bracket bolt
58.9 - 78.5
6.0 - 8.0
43.4 - 57.8
Transmission upper mounting bolt  (Transmission=>Engine)
42.2 - 53.9
4.3 - 5.5
31.1 - 39.8
Transmission lower mounting bolt  (Engine=>Transmission)
42.2 - 48.1
4.3 - 4.9
31.1 - 35.4
42.2 - 53.9
4.3 - 5.5
31.1 - 39.8
TCM bracket mounting nut
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Engine support fixture (bar)
09200-3N000

Used for holding engine assembly when removing / installing transmission
Used with the supporter (09200-2S000) adapter (09200-4X000)
※Refer to the engine support fixture assembly drawing below.
Engine support fixture (supporter)
A: 09200-2S000
B: 09200-2S100
C: 09200-2S200

Used for holding engine assembly when removing / installing transmission
Used with the bar (09200-3N000) and adapter (09200-4X000)
※Refer to the engine support fixture assembly drawing below.
Engine support fixture (adapter)
09200-4X000

Used for holding engine assembly when removing / installing transmission
Used with the bar (09200-3N000) and supporter (09200-2S000)
※Refer to the engine support fixture assembly drawing below.
Oil seal installer
09430-C1190

Installation of transaxle case oil seal.
Used with the handle (09231-H1100)
Handle
09231-H1100

Installation of transaxle case oil seal.
Used with the installer (09430-C1190)
Inhibitor switch guide pin
09480-A3800

Used for fixing "N" range when installing inhibitor switch
Dual clutch remover
09430-C1180

Used for removing dual clutch assembly
Dual clutch installer
09430-2A240

Used for installing dual clutch assembly
Clutch actuator remover
09430-A5100

Used for removing clutch actuator assembly
Clutch actuator adjuster
09430-C1300

Used for adjusting clutch actuator
Used with the clutch actuator adjustment jig (09430-C1302)
Clutch actuator adjustment jig
09430-C1302

Used for adjusting clutch actuator
Used with the clutch actuator adjuster (09430-C1300)

※ Engine support fixture special tool assembly drawing

Troubleshooting
Troubleshooting

Trouble symptom
Probable cause
Remedy
Warning lamp "E" is illuminated
(Driving is only possible with 1/R gear)
DCT learning not performed
Perform the DCT manual learning procedure.
Driving impossible at odd gear
Clutch actuator (Clutch motor 1 or position sensor 1 is faulty)
Replace the clutch actuator assembly.
Gear actuator (Shift motor 1, position sensor 1, select solenoid 1 or position sensor 1 is faulty)
Replace the gear actuator assembly.
Input speed sensor 1 is faulty
Replace the input speed sensor.
Faulty gears (1, 3, 5, 7)
Replace the gear.
Faulty clutch 1
Replace the dual clutch assembly.
Faulty clutch engagement bearing 1
Replace the clutch engagement bearing
Driving impossible at even gear
Clutch actuator (Clutch motor 2 or position sensor 2 is faulty)
Replace the clutch actuator assembly.
Gear actuator (Shift motor 2, position sensor 2, select solenoid 2 or position sensor 2 is faulty)
Replace the gear actuator assembly.
Input speed sensor 2 is faulty
Replace the input speed sensor.
Faulty gears (2, 4, 5, 6 , R)
Replace the gear.
Faulty clutch 2
Replace the dual clutch assembly.
Faulty clutch engagement bearing 2
Replace the clutch engagement bearing
Driving impossible 
Faulty TCM
Replace the TCM.
Simultaneous failure of odd & even systems
Replace the dual clutch assembly or gear.
Simultaneous failure of inhibitor switch & shift lever sensor
Replace the inhibitor switch.
Manual mode disabled
Faulty inhibitor switch
Replace the inhibitor switch.
Faulty shift lever sensor
Replace the shift lever.
Faulty manual mode switch
Replace the manual mode switch housing.
Noise
Oil level (Low)
Refill the transmission with oil after inspecting the parts (oil, seal, drain plug, and filler plug).
Oil (Wrong type)
Replace the oil.
Synchronizer ring (Worn or damaged)
Replace the synchronizer ring.
Gear (Worn or damaged)
Replace the gear.
Bearing (Worn or damaged)
Replace the bearing.
Oil leakage
Oil level (High)
Inspect the oil level.
Gasket (Damaged)
Replace the gasket.
Oil seal (Worn or damaged)
Replace the oil seal.
Hard shifting or impossible to shift
Oil (Wrong type)
Replace the oil.
Shift fork (Worn)
Replace the shift fork.
Synchronizer ring (Worn or damaged)
Replace the synchronizer ring.
Gear (Worn or damaged)
Replace the gear.
Hub sleeve (Worn or damaged)
Replace the hub sleeve.

Vehicle Speed Sensor
Specifications Specification Item  Specification  Type Hall sensor Working voltage  6.5 ...

Dual Clutch Transmission Control System
Description and operation Description The Dual Clutch Transmission (DCT) control system measures data required for identifying the state of control target and computes the appropriate ...

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