Kia Cee'd: Dual Clutch Transmission Assembly / Dual Clutch Transmission(DCT) Repair procedures

Removal
1.
Remove the engine cover.
(Refer to Engine Mechanical System - "Engine cover")
2.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechanical System - "Air cleaner")
3.
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
4.
Remove the ECM.
(Refer to Fuel System - "Engine Control Module (ECM)")
5.
Disconnect the shift actuator connector (A) and select actuator connector (B). Then remove the wire fixing clip.

6.
Disconnect the odd clutch actuator motor connector (A), and then remove the wire fixing clip.

7.
Disconnect the inhibitor switch connector (A).

8.
Remove the bolt (A), and then disconnect the ground wire.

9.
Disconnect the input shaft speed sensor 2 (A) and input shaft speed sensor 1 (B) connectors.

10.
Remove the nut (A) and bolt (B). Then remove the shift cable (C).
Tightening torque:
(A) 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
(B) 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.4 ~ 19.5 lb-ft)

11.
Remove the Dual Clutch Transmission(DCT) upper mounting bolts (A: 2ea, B: 2ea).
Tightening torque:
(A,B) 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

12.
Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
13.
Assemble the engine support fixture.
(Refer to Special Service Tools - "Engine support fixture assembly drawing")
14.
Install the engine support fixture special tool(A) on the engine room.
15.
Hang the ring (B) on the engine hanger, support the engine.
  
To prevent slip, the support supports the body securely.

16.
Remove the mounting cover (A).

17.
Support the Dual Clutch Transmission(DCT) on the lower section, and remove the DCT support bracket mounting bolt (A).
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

18.
Loosen the mounting bolt and then remove the Dual Clutch Transmission(DCT) support bracket (A).
Tightening torque:
58.8 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

19.
Remove the under cover (A).
Under cover tightening torque:
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

20.
Disconnect the even clutch actuator motor connector (A).

21.
Remove the drive shaft.
(Refer to Driveshaft and Axle - "Front Driveshaft")
22.
Loosen the mounting bolt and then remove the bracket (A).

23.
Remove the drive shaft cover (A).

24.
Remove the mounting bolts (A, B) after supporting the transmission by a jack.
Tightening torque:
(A) 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
(B) 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

25.
Remove the transaxle while slowly lower the jack.
  
Be careful not to damage other system or parts near by when removing the transaxle assembly.
Installation
  
If the transmission case oil seal is damaged, and there is leak, then replace the oil seal with a new one.
Use the oil seal installer (09453-2F300) when you install the oil seal.
1.
Align the external damper spline (A) on the engine side with the dual clutch spline (B).

2.
First insert the input shaft (A) to the engine pilot bearing (B) and then affix the transmission towards the engine.
  
If the shaft is not aligned, the Dual clutch interferes with the external damper, and may cause the support washer to be damaged or broken. The broken chip may enter the inside.

3.
Make sure that there is no gap on the matching side when assembling the engine block (A) and the transmission.
Then tighten the bolts (engine and transmission mounting bolts).

  
If the bolt is tightened while there is a gap, then the external damper finger(A) may be damaged or broken.
The damaged chips may lodge between the clutches and create a persistent contact problem.

4.
Refill Dual Clutch Transmission(DCT) oil.
(Refer to Dual Clutch Transmission Assembly - "Fluid")
5.
Always use the GDS to delete the error code (DTC) after Dual Clutch Transmission(DCT) and TCM maintenance.
The error code (DTC) cannot be deleted by disconnecting the battery terminal.
6.
You must perform TCM learning after you change the transmission to prevent delayed transmission shift and shock during acceleration or when starting to move.
(‏Refer to Dual Clutch Transmission(DCT) System - "Repair Procedure")
Dual Clutch Transmission(DCT) Components and components location
Components   1. Odd clutch actuator motor 2. Even clutch actuator motor 3. Input shaft speed sensor 2 4. Intput shaft speed sensor 1 5. Inhibitor swi ...

Transmission Gear Oil Specifications
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