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Home >> Hyundai >> 2018 >> Tucson Sport, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 21 (Dual Clutch Transmission Control System - 1.6L) >> Clutch Actuator Assembly >> Repair Procedures >> Adjustment

Repair Procedures: Adjustment

WARNING: This page is about a different variant/trim than selected.
NOTE:
  • 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 Initialize the rod length.

A. Rewinding the rod to adjust rod length (when only the clutch actuator is replaced) 

NOTE:
  • 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 - 3 of the following procedure.
  2. Install the faulty clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts and bolts.
    G12609234Courtesy of HYUNDAI MOTOR AMERICA
  3. Slightly pull the lever of the clutch actuator removed from the vehicle and measure the length of each old rod (C).

    Length of the old rod (C):  Length from the reference plane (A) to the end of the rod (B).

    1. Clutch actuator 1
    2. Clutch actuator 2
      G12609235Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • If the rod length is less than 46 mm (1.8110 in.), replace all of the dual clutch assembly, clutch actuator, and engagement bearing.
  4. 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. 5 - 14 of the following procedure.
  5. Install the faulty clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts and bolts.
    G12609236Courtesy of HYUNDAI MOTOR AMERICA
  6. Fix the pull rod to hook (B) and then remove sealing rubber (A).
    G12609237Courtesy of HYUNDAI MOTOR AMERICA
  7. Slightly pull the lever of the new clutch actuator and measure the length of each new rod (C).

    Length of the new rod (C):  Length from the reference plane (A) to the end of the rod (B).

    1. Clutch actuator 1
    2. Clutch actuator 2
      G12609238Courtesy of HYUNDAI MOTOR AMERICA
  8. With the clutch actuator fixing jig (09430-C1302) (A) installed, stand the clutch actuator vertically.
  9. After standing it vertically, remove the hook (B) from the rod.
    G12609239Courtesy of HYUNDAI MOTOR AMERICA
  10. Press the end part of rod (A) and release the pressing force when you see the nut bump (B).
    G12609240Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • Light inside of the hole (C) and check the nut bump (B) inside of it.
    • Repeat the operation if the nut bump (B) does not come down to the assembly hole position.
    • The nut bump (B) can be moved up a little by sealing boot if the pressing force is released.
  11. Insert a special tool (09430-C1300) (A) to a sealing rubber hole.

    Rotate the SST clockwise and adjust the length of the new clutch actuator's rod to the "length of old rod", which was measured at step No. 3.

    Increasing (+) rod length:  Rotate counter-clockwise / once +0.25 mm (+0.0098 in.)

    Shortening (-) rod length:  Rotate clockwise / once -0.25 mm (-0.0098 in.)

    G12609241Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • Perform the same procedure for the opposite side rod.
    NOTE:
    • Be aware not to break the clutch actuator caused by break away inner parts when the SST over rotates clockwise.
    • If the "length of the clutch actuator's new rod" is not adjusted to the "length of the old rod" measured at step No. 3, the DCT shift shock may occur or driving may be impossible.
  12. With the clutch actuator fixing jig (09430-C1302) (A) mounted, maintain the level of the clutch actuator.
  13. With the fixing jig (094320-C1302) levelled, install the hook (B) on the clutch actuator.
    G12609242Courtesy of HYUNDAI MOTOR AMERICA
  14. Slightly pull the lever of the clutch actuator and check whether the "length of the rod which the final adjustment is finished" is same with the "length of the old rod" measured at step No. 3.

    Rod length (C):  Length from the reference plane (A) to the end of the rod (B).

    1. Clutch actuator 1
    2. Clutch actuator 2
    G12609243Courtesy of HYUNDAI MOTOR AMERICA
  15. Install the sealing rubber (A).
    G12609244Courtesy of HYUNDAI MOTOR AMERICA
  16. Remove the clutch actuator assembly from the special tool (09430-C1302).

B. Initializing the rod length (When only the dual clutch assembly is replaced or Both dual clutch assembly and clutch actuator is replaced) 

NOTE:
  • Be sure to perform it when you have replaced the dual clutch assembly but reuse the clutch actuator.
  • Perform the procedure when both the dual clutch assembly and clutch actuator are replaced.
  • 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 faulty clutch actuator (A) on special service tool (09430-C1302) and fix the actuator using nuts and bolts.
    G12609245Courtesy of HYUNDAI MOTOR AMERICA
  3. Fix the pull rod to hook (B) and then remove sealing rubber (A).
    G12609246Courtesy of HYUNDAI MOTOR AMERICA
  4. Slightly pull the lever of the clutch actuator removed from the vehicle and measure length of each rod (C). If the length is shorter than the initialization length, you need to perform initialization.

    Rod length (C):  Length from the reference plane (A) to the end of the rod (B).

    Initialize rod length:  71.5 - 72.5 mm (2.8149 - 2.8543 in.)

    1. Clutch actuator 1
    2. Clutch actuator 2
    G12609247Courtesy of HYUNDAI MOTOR AMERICA
  5. Stand the clutch actuator vertically with SST (09430-C1302) (A) installed.
  6. After standing it vertically, remove the hook (B) from the rod.
    G12609248Courtesy of HYUNDAI MOTOR AMERICA
  7. Press the end part of rod (A) and release the pressing force when you see the nut bump (B).
    G12609249Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • Light inside of the hole (C) and check the nut bump (B) inside of it.
    • Repeat the operation if the nut bump (B) does not come down to the assembly hole position.
    • The nut bump (B) can be moved up a little by sealing boot if the pressing force is released.
  8. Insert a special tool (09430-C1300) (A) to a sealing rubber hole.

    Rotate the SST counter-clockwise and adjust the length of the clutch actuator's rod.

    Increasing (+) rod length:  Rotate counter-clockwise / once +0.25 mm (+0.0098 in.)

    Shortening (-) rod length:  Rotate clockwise / once -0.25 mm (-0.0098 in.)

    G12609250Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • Perform the same procedure for the opposite side rod.
    NOTE:
    • Be aware not to break the clutch actuator caused by break away inner parts when the SST over rotates clockwise.
    • If the rod length is not initialized to 71.5 - 72.5 mm (2.8149 - 2.8543 in.) during initialization of wear compensation, DCT shift shock may occur or driving may be impossible.
  9. With the clutch actuator fixing jig (09430-C1302) (A) mounted, maintain the level of the clutch actuator.
  10. With the fixing jig (094320-C1302) levelled, install the hook (B) on the clutch actuator.
    G12609251Courtesy of HYUNDAI MOTOR AMERICA
  11. Slightly pull the lever of the clutch actuator and check whether the "length of the rod which the final adjustment is finished" is same with the "rod's initialized length".

    Rod length (C):  Length from the reference plane (A) to the end of the rod (B).

    (Initialize rod length:  71.5 - 72.5 mm (2.8149 - 2.8543 in.)

    1. Clutch actuator 1
    2. Clutch actuator 2
    G12609252Courtesy of HYUNDAI MOTOR AMERICA
  12. Install the sealing rubber (A).
    G12609253Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the clutch actuator assembly from the special tool (09430-C1302).
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