Repair Procedures: Adjustment

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

CAUTION: If you replaced the dual clutch assembly or clutch actuator, be sure to perform wear compensation by referring to the following table.

Case	Replaced Part	Wear Compensation (Clutch Actuator)
A	Clutch actuator only	Rewind the rod to adjust rod length.
B	Double clutch assembly only	Initialize the rod length.
C	Both dual clutch assembly and clutch actuator	No action necessary

Rewinding the rod to adjust rod length (when only the clutch actuator is replaced)
CAUTION: Be sure to perform it when you have replaced the clutch actuator but reuse the dual clutch assembly. It is performed to adjust the rod length of a new clutch actuator to that of an old clutch actuator.
1. Remove the clutch actuator assembly.
  (Refer to Clutch Actuator Assembly - "REMOVAL ")
  
  Information
  
  To measure the rod length of an old clutch actuator, perform the steps No. 2 - 6 of the following procedure.
2. Install the faulty clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts.
  
  Fig 1: Installing Faulty Clutch Actuator On Special Service Tool (09430-C1302)
  Courtesy of HYUNDAI MOTOR AMERICA
3. Remove clutch actuator motor (A) and ground bolt (B).
  
  Fig 2: Locating Clutch Actuator Motor And Ground Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
4. Insert a special tool (09430-C1302) to the ball screw and rotate it counter-clockwise until you hear a "click" sound and the rod is rewound completely.
  CAUTION:
  - In some cases, you may not hear a "click" sound even if you rotate the tool counter-clockwise. In such vehicles, rotate the tool counter-clockwise until it won't rotate anymore.
  - You need to stop rotating the tool at the position where it won't rotate anymore. If you continue to rotate it counterclockwise, the actuator may become damaged.
  Fig 3: Inserting Special Tool (09430-C1302) To Ball Screw
  Courtesy of HYUNDAI MOTOR AMERICA
5. Measure the rewound rod length (C) of the clutch actuator removed from the vehicle.
  Rewound length (C): Distance from the reference plane (A) to the end of the rod (B)
  
  Fig 4: Measuring Rewound Rod Length Of Clutch Actuator
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: If the rod length is less than 25 mm, replace all of the dual clutch assembly, clutch actuator, and engagement bearing.
6. Pull the lever (A) until "click" sound is heard and then measure the length to check for pull rod length of faulty clutch actuator (B).
  
  Fig 5: Pulling Lever
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 6: Measuring Length To Checking For Pull Rod Length Of Faulty Clutch Actuator
  Courtesy of HYUNDAI MOTOR AMERICA
7. Remove the clutch actuator from the special service tool (09430-C1302).
  Information
  
  To match the rod length of a new clutch actuator with that of the clutch actuator removed from the vehicle, perform the steps No. 8 - 14 of the following procedure.
8. Install the new clutch actuator (A) on special tool (09430-C1302) and fix the actuator using nuts.
  
  Fig 7: Installing Clutch Actuator On Special Tool (09430-C1302)
  Courtesy of HYUNDAI MOTOR AMERICA
9. Remove clutch actuator motor (A) and ground bolt (B).
  
  Fig 8: Locating Clutch Actuator Motor And Ground Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
10. Insert a special tool (09430-C1302) to the ball screw and rotate it counter-clockwise until you hear a "click" sound and the rod is rewound completely.
  CAUTION:
  - In some cases, you may not hear a "click" sound even if you rotate the tool counter-clockwise. In such vehicles, rotate the tool counter-clockwise until it won't rotate anymore.
  - You need to stop rotating the tool at the position where it won't rotate anymore. If you continue to rotate it counterclockwise, the actuator may become damaged.
  Fig 9: Inserting Special Tool (09430-C1302) To Ball Screw
  Courtesy of HYUNDAI MOTOR AMERICA
11. Fix the pull rod to hook (B) and then remove sealing rubber (A).
  
  Fig 10: Locating Hook And Sealing Rubber
  Courtesy of HYUNDAI MOTOR AMERICA
12. Insert a special tool (09430-C1300) to a sealing rubber hole.
  Rotate the tool clockwise to match the rod length of a new clutch actuator with the "rewound length" measured at the step No. 5.
  
  CAUTION: If the rewound length of a new clutch actuator is not the same as that of the clutch actuator removed from the vehicle, DCT shift shock may occur.
  
  Fig 11: Rotating Tool Clockwise
  Courtesy of HYUNDAI MOTOR AMERICA
13. Pull the lever (A) until you hear a "click" sound and check if the full rod length of a new clutch actuator is the same as that of the clutch actuator removed from the vehicle, which was measured at the step No. 6.
  
  Fig 12: Pulling Lever
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 13: Checking Full Rod Length Of Clutch Actuator
  Courtesy of HYUNDAI MOTOR AMERICA
14. Install the sealing rubber (A).
  
  Fig 14: Locating Sealing Rubber
  Courtesy of HYUNDAI MOTOR AMERICA
15. Install the clutch actuator motor (A) and ground (B).
  NOTE: Do not reuse a ground bolt (B), O-ring (C), and sealing bolt (D).
  
  Tightening torque:
  
  3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  Fig 15: Locating Clutch Actuator Motor, Ground Bolt, O-Ring And Sealing Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
Initializing the rod length (when only the dual clutch assembly is replaced)
CAUTION: Be sure to perform it when you have replaced the dual clutch assembly but reuse the clutch actuator.
It is performed to adjust the rod length of an old clutch actuator to that of a new clutch actuator.
1. Remove the clutch actuator assembly.
  (Refer to Clutch Actuator Assembly - "REMOVAL ")
2. Install the clutch actuator (A) on special service tool (09430-C1302) and fixing the actuator using nuts.
  
  Fig 16: Installing Clutch Actuator On Special Service Tool (09430-C1302)
  Courtesy of HYUNDAI MOTOR AMERICA
3. Remove clutch actuator motor (A).
  
  Fig 17: Locating Clutch Actuator Motor
  Courtesy of HYUNDAI MOTOR AMERICA
4. Insert a special tool (09430-C1302) to the ball screw and rotate it counter-clockwise until you hear a "click" sound and the rod is rewound completely.
  CAUTION:
  - In some cases, you may not hear a "click" sound even if you rotate the tool counter-clockwise. In such vehicles, rotate the tool counter-clockwise until it won't rotate anymore.
  - You need to stop rotating the tool at the position where it won't rotate anymore. If you continue to rotate it counterclockwise, the actuator may become damaged.
  Fig 18: Inserting Special Tool (09430-C1302) To Ball Screw
  Courtesy of HYUNDAI MOTOR AMERICA
5. Set a T-plate (B) at a 49 mm (1.9291 in.) position, which is the rod length of a new clutch actuator, and fix it with a nut (A).
  New part length: 49 mm (1.9291 in.)
  - If you replace both dual clutch assembly and clutch actuator with new ones, do not perform separate initialization to set the rod length to 49 mm.
6. Remove the sealing rubber (C).
  
  Fig 19: Checking T-Plate Setting Dimension
  Courtesy of HYUNDAI MOTOR AMERICA
7. Insert special service tool (09430-C1300) to the sealing rubber hole and then move to the T plates (A) by rotating clockwise.
  CAUTION:
  - If the rod length does not change even when you rotate the special tool three turns or more, slightly pull the end of the rod with your hands so that the rod touches the T plate, and then stop rotating the tool.
  - Rotate the tool until the rod touches the T-plate.
  - You need to stop rotating the tool when the rod touches the T-plate because, if you continue rotating the tool, the rod does not stop and continue to move.
  - If you rotate the tool too much, the rod may be separated from the actuator.
  Information
  
  Rotating the tool 360° for four times moves the rod by 1 mm.
  
  Fig 20: Inserting Special Service Tool (09430-C1300) To Sealing Rubber Hole
  Courtesy of HYUNDAI MOTOR AMERICA
8. Fix the pull rod to hook (B) and install the sealing rubber (A).
  
  Fig 21: Locating Hook And Sealing Rubber
  Courtesy of HYUNDAI MOTOR AMERICA
9. Pull the lever (A) until "click" sound is heard and then measure the length again to check for specified length (B).
  Specified length: 71.5 mm (2.8150 in.)
  
  CAUTION: If the rod length is not initialized to 71.5 mm during initialization of wear compensation, DCT shift shock may occur.
  
  Fig 22: Pulling Lever
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 23: Measuring Length Again To Checking For Specified Length
  Courtesy of HYUNDAI MOTOR AMERICA
10. Install the clutch actuator motor (A) and ground (B).
  NOTE: Do not reuse a ground bolt (B), O-ring (C), and sealing bolt (D).
  
  Tightening torque:
  
  3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  Fig 24: Locating Clutch Actuator Motor, Ground Bolt, O-Ring And Sealing Bolt
  Courtesy of HYUNDAI MOTOR AMERICA