Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE:

Check that the input shaft spline part (A) is sufficiently greased before installing the dual clutch assembly. If the input shaft spline part is not greased, apply the grease to 10 mm on each spline end.
If an excessive amount of grease is applied, it may get scattered by centrifugal force, contaminating the clutch disc. This can lead to loss of friction force.

Specified grease : Extreme pressure grease for vehicle

Quantity : 0.15 - 0.25 g

Fig 1: Checking Input Shaft Spline Part

Courtesy of KIA MOTORS AMERICA, INC.

If dual clutch assembly needs replacement, perform the clutch wear compensation Initialize.
1. Remove the fork cover (A).
  
  Fig 2: Locating Fork Cover
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the clutch actuator assembly (A).
  
  Fig 3: Locating Clutch Actuator Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
3. Perform the clutch wear compensation Initialize.
  (Refer to Dual Clutch Transmission Control System - "CLUTCH ACTUATOR ASSEMBLY ")
4. Install 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)
  
  Fig 4: Locating Clutch Actuator Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
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)
  
  Fig 5: Locating Fork Cover
  Courtesy of KIA MOTORS AMERICA, INC.
By using the dual clutch installer (09430-2A240), place the dual clutch assembly.

Fig 6: Placing Dual Clutch Assembly Using Dual Clutch Installer (09430-2A240)
Courtesy of KIA MOTORS AMERICA, INC.
Install the special service tool (09430-2A240) on the clutch housing side. Then, install the dual clutch assembly (A) by rotating the shaft of service tool.

Fig 7: Installing Special Service Tool (09430-2A240) On Clutch Housing Side
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring (A).

Fig 8: Locating Snap Ring
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Install the spline hub (B) and the retaining ring (A).

Fig 9: Locating Spline Hub And Retaining Ring
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Install the dual clutch transmission to vehicle.
(Refer to REMOVAL ) )
Perform the clutch touch point learning procedure using the KDS/GDS.

Fig 10: Scantool Display - Vehicle S/W Management
Courtesy of KIA MOTORS AMERICA, INC.