| VELOSTER(FS) >2012 > G 1.6 GDI > Dual Clutch Transmission(DCT) System > Dual Clutch Transmission Assembly > Dual Clutch Transmission(DCT)>Repair procedures |

Removal
1. | Remove the following parts first:
A. | Engine cover (A) (Refer to the Intake and Exhaust System of EM Group.)
B. | Air cleaner assembly (B) and air duct (C) (Refer to the Intake and Exhaust System of EM Group.)
C. | Battery and Tray (D) (Refer to the Charging System of EE Group.)
D. | ECM (E) (Refer to the Engine Control Module of FL Group.)
2. | Disconnect the shift actuator connector (A) and select actuator connector (B). Then remove the wire fixing clip.
3. | Disconnect the odd clutch actuator motor connector (A), and then remove the wire fixing clip.
4. | Disconnect the inhibitor switch connector (A).
5. | Remove 1 bolt (A), and then disconnect the ground wire.
6. | Disconnect the input shaft speed sensor 2 (A) and input shaft speed sensor 1 (B) connectors.
7. | 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)
8. | Remove the DCT(Dual Clutch Transmission) 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)
9. | Use the special tools to support the engine and transmission assembly. (Supporter SST No.: 09200 - 2S100/2S200, beam SST No.: 09200 - 38001/3N000, adapter SST No.: 09200 - 4X000)
10. | Remove the mounting cover (A).
11. | Support the DCT(Dual Clutch Transmission) 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)
12. | Loosen the mounting bolt and then remove the DCT(Dual Clutch Transmission) support bracket (A).
Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
13. | 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)
14. | Disconnect the even clutch actuator motor connector (A).
15. | Remove the sub frame assembly. (Refer to the "Front Suspension System(Sub Frame)" in SS Group.)
16. | Drive shaft (Refer to "Drive shaft assembly " in DS group.)
17. | Loosen the mounting bolt and then remove the bracket (A).
18. | Remove the drive shaft cover (A).
19. | Support the DCT(Dual Clutch Transmission) with only a jack, and then loosen the mounting bolts (A: 2, B: 3). Then lower the jack slowly, and remove the DCT(Dual Clutch Transmission) assembly.
Tightening torque: (A,B) 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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 (09431-26100) 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 DCT(Dual Clutch Transmission) oil. (‏Refer to the DCT(Dual Clutch Transmission)" Procedure" in this group.)
5. | Always use the GDS to delete the error code (DTC) after DCT(Dual Clutch Transmission) 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 the DCT(Dual Clutch Transmission)" Procedure" in this group.)