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Home >> Kia >> 2020 >> Soul GT Line Turbo >> Repair and Diagnosis >> Transmission >> Transmission Control Systems >> Double Clutch Transmission Control System - 1.6L >> Clutch Actuator Assembly >> Repair Procedures >> Adjustment

Repair Procedures: Adjustment

NOTE: Make sure to proceed compensate wear procedure referring to table below in case of a dual clutch assembly or a clutch actuator replacement.
  Replacement part Remedy
A If only 'clutch actuator' has been replaced Need to rewind rod length
B If only 'double clutch assembly' has been replaced Need to initialize rod length
C If 'double clutch assembly' and 'clutch actuator' both have been replaced Need to initialize rod length
  1. Rewinding rod length (if replacing a clutch actuator only) 
    NOTE: Make sure to perform rewinding rod length procedure if replacing a clutch actuator only and reusing a dual clutch assembly.
    This procedure is to adjust length of a new clutch actuator rod as an old clutch actuator rod length.
    1. Remove the clutch actuator.

      (Refer to Clutch Actuator Assembly - " REMOVAL  ") 

      Information 

      Measure the length of the existing clutch actuator rod which had been installed referring to step 2~3.

    2. Fix the clutch actuator (A) which had been removed from vehicle with nut (B) after installing on SST (09430-C1302).
      G13281038Courtesy of KIA MOTORS AMERICA, INC.
    3. Measure and write down length of the old rod in condition of pulling clutch actuator lever.

      Old rod length (A):  length from the base surface (C) to the end of the rod (B).

      1. Clutch Actuator rod 1
      2. Clutch Actuator rod 2
      G13281039Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Replace all of double clutch assembly, clutch actuator and engagement bearing if the rod length is shorter than 46mm/1.81 in.
    4. Remove the clutch actuator from SST (09430-C1302).

      Information 

      Adjust length of the new clutch actuator rod referring to the procedure 4~16.

    5. Fix with nut (B) after installing the new clutch actuator (A) on SST (09430-C1302).
      G13281040Courtesy of KIA MOTORS AMERICA, INC.
    6. Fix the rod on hook (B) after removing sealing rubber (A).
      G13281041Courtesy of KIA MOTORS AMERICA, INC.
    7. Write down after measuring each length of the new rod (A) in condition of pulling the new clutch actuator lever.

      New rod length (A):  length from the base surface (C) to the end of the rod (B).

      1. Clutch Actuator rod 1
      2. Clutch Actuator rod 2
      G13281042Courtesy of KIA MOTORS AMERICA, INC.
    8. Stand clutch actuator vertically which is installed with SST (09430-C1302).
    9. Disassemble the clutch actuator hook (A) from the lever of SST.
      G13281043Courtesy of KIA MOTORS AMERICA, INC.
    10. Press the end part of rod (A) and release the pressing force when you see the nut bump (B).
      G13281044Courtesy of KIA MOTORS AMERICA, INC.

      Information 

      • Light inside of the hole and check the bump 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.

      Extend length of rod (+):  counterclockwise rotation/1 rotation (+0.25 mm/+0.009 in)

      Shorten length of rod (-):  clockwise rotation/1 rotation (-0.25 mm/-0.009 in)

    11. Put SST (09430-C1300) into sealing rubber hole.

    Adjust length of a new clutch actuator rod by rotating SST clockwise to 'an old rod length' which measured in procedure number 3.

    Extend length of rod (+):  counterclockwise rotation/1 rotation (+0.25 mm/+0.009 in)

    Shorten length of rod (-):  clockwise rotation/1 rotation (-0.25 mm/-0.009 in)

    G13281045Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    Perform same procedure on opposite side rod.

    NOTE:
    • It can be a cause of impossibility to drive or transmission shock of DCT if 'length of the new clutch actuator rod' has not been adjusted same as 'length of the old clutch actuator rod' which is measured in procedure number 3.
  2. Lay the clutch actuator horizontally with SST (09320-C1302) installed.
  3. Put the clutch actuator hook (A) into the SST lever.
    G13281046Courtesy of KIA MOTORS AMERICA, INC.
  4. Check if 'rod length of the clutch actuator', which is done with adjusting in state of pulling its lever, and 'rod length of the old clutch actuator', which is measured in step number 3, are same.

    Rod length (A):  length from the base surface (C) to the end of the rod (B).

    1. Clutch Actuator rod 1
    2. Clutch Actuator rod 2
    G13281047Courtesy of KIA MOTORS AMERICA, INC.
  5. Install sealing rubber (A).
    G13281048Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the clutch actuator from SST (09430-C1302)
  7. Rod length initialization (when replace only dual clutch assembly) 
NOTE: Make sure to perform this procedure if replacing only dual clutch assembly but reusing clutch actuator.
This procedure is adjusting changed existing clutch actuator rod length to a new product rod length.
  1. Remove the clutch actuator.

    (Refer to Clutch Actuator Assembly - " REMOVAL  ") 

  2. Fix the clutch actuator (A) which had been removed from vehicle with nut (B) after installing on SST (09430-C1302).
    G13281049Courtesy of KIA MOTORS AMERICA, INC.
  3. Fix the rod to hook after removing sealing cover (A).
    G13281050Courtesy of KIA MOTORS AMERICA, INC.
  4. Initialization procedure will be needed if the measure value of each rod length, which measured in state of pulling lever on removed clutch actuator from vehicle, is shorter than initializing length specification.

    Rod length (A):  length from the base surface (C) to the end of the rod (B).

    (initialization length: 71.5 ~ 72.5 mm/2.81 ~ 2.85 in) 

    1. Clutch Actuator rod 1
    2. Clutch Actuator rod 2
    G13281051Courtesy of KIA MOTORS AMERICA, INC.
  5. Stand the clutch actuator vertically with SST (09430-C1302) installed.
  6. Remove the clutch actuator hook (A) from SST lever.
    G13281052Courtesy of KIA MOTORS AMERICA, INC.
  7. Press the end part of rod (A) and release the pressing force when you see the nut bump (B).
    G13281053Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    • Light inside of the hole and check the bump 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. Put SST (09302-C1300) into sealing rubber hole.

    Adjust length of the clutch actuator rod by rotating SST counterclockwise.

    Extend length of rod (+):  counterclockwise rotation/1 rotation (+0.25 mm/+0.009 in)

    Shorten length of rod (-):  clockwise rotation/1 rotation (-0.25 mm/-0.009 in)

    G13281054Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    Perform same procedure on opposite side rod.

    NOTE:
    • Be aware not to break the clutch actuator caused by break away inner parts when the SST over rotates counterclockwise.
    • It can be a cause of impossibility to drive or transmission shock of DCT if the rod length is not initialized to (71.5 ~ 72.5 mm/2.81 ~ 2.85 in) when the initialization of compensate wear procedure.
  9. Lay clutch actuator horizontally with SST (09320-C1302) installed.
  10. Put clutch actuator hook (A) into SST lever.
    G13281055Courtesy of KIA MOTORS AMERICA, INC.
  11. Check if 'clutch actuator rod length', which is finally done with adjustment, and 'clutch actuator rod initialization length' are same while pulling clutch actuator lever.

    Rod length (A):  length from the base surface (C) to the end of the rod (B).

    (initialization length:  71.5 ~ 72.5 mm/2.81 ~ 2.85 in)

    1. Clutch Actuator rod 1
    2. Clutch Actuator rod 2
    G13281056Courtesy of KIA MOTORS AMERICA, INC.
  12. Install sealing rubber (A).
    G13281057Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the clutch actuator from SST (09430-C1302).
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