Hyundai Ioniq: Dual Clutch System / Dual Clutch Assembly. Repair procedures

Hyundai Ioniq (AE) 2017-2025 Service Manual / DCT(Dual Clutch Transmission) System / Dual Clutch System / Dual Clutch Assembly. Repair procedures

Removal

1.	Remove the dual clutch transmission from the vehicle. (Refer to Dual Clutch Transmission System - "Dual Clutch Transmission")

2.	Remove the hybrid motor assembly from the dual clutch transmission assembly. (Refer to Hybrid Motor System - "Hybrid Motor Assembly")

3.	Remove the retaining (A) and then removing the spline hub (B).

4.	Remove the snap ring (A).

5.	Remove the dual clutch assembly (A) by using the special service tool [SST No.: 09430-C1180].

Installation

•	Check the applied state of grease on input shaft spline part (A) before installing the dual clutch assembly. If there is no grease on input shaft spline part, should apply the grease on each spline end to 10mm.

•	If excessively applied grease, grease can be scattered by centrifugal force which can contaminate the clutch disc. This can cause a loss of friction force

Specified grease : Extreme pressure grease for vehicle

Quantity : 0.15 - 0.25g

1.	Install the SST (No.:09430-2A240) on the support bearing with in the dual clutch assembly (A).

2.	Install the special service tool (09430-2A240) on the clutch housing side. Then, install the dual clutch assembly (A) by rotating the shaft of service tool.

Install the snap ring (A).

•	When installing make sure to ensure that the dual clutch snap ring is seatted securely in place.

•	When installing never reuse the deformed dual clutch snap ring.

Install the spline hub (B) and the install the retaining ring (A).

•	After installation, check the retaining ring. (Be sure seated of the support washer in eight places.)

5.	Install the hybrid motor assembly in the dual clutch transmission assembly. (Refer to Hybrid Motor System - "Hybrid Motor Assembly")

6.	Install the dual clutch transmission to vehicle. (Refer to Dual Clutch Transmission System - "Dual Clutch Transmission")

7.	Perform the work procedures for abrasion compensation reset after installing the new dual clutch assembly. (Refer to Clutch Actuator Assembly - "Adjustment")

8.	Perform the clutch touch point learning procedure using the GDS after replacing the dual clutch assembly.

Dual Clutch Assembly. Components and components location

C..

Clutch Engagement Fork and Engagement Bearing. Components and components location

C..

Other information:

Hyundai Ioniq (AE) 2017-2025 Service Manual: Description and operation

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Hyundai Ioniq (AE) 2017-2025 Service Manual: Troubleshooting

Troubleshooting Symptom Possible cause Remedy Hard steeringImproper front wheel alignmentExcessive turning resistance of lower arm ball jointLow tire pressureNo power assistCorrectReplaceAdjustRepair and replacePoor return of steering wheel to centerImproper front wheel alignmentCorrectPoor or rough rideImproper front wheel alignmentMalfunctioning shock absorberBroken or worn stabilizerBroken or worn coil springWorn lower arm bushingCorrectRepair or replaceReplaceReplaceReplace the lower arm assemblyAbnormal tire wearImproper front wheel alignmentImproper tire pressureMalfunctioning shock absorberCorrectAdjust or replaceReplaceWanderingImproper front wheel alignmentPoor turning resistance of lower arm ball jointLoose or worn lower arm bushingCorrectRepairRetighten or replaceVehicle pulls to one sideImproper front wheel alignmentExcessive turning resistance of lower arm ball jointBroken or worn coil springBent lower armCorrectReplaceReplaceRepairSteering wheel shimmyImproper front wheel alignmentPoor turning resistance of lower arm ball jointBroken or worn stabilizerWorn lower arm bushingMalfunctioning shock absorberBroken or worn coil springCorrectReplaceReplaceReplaceReplaceReplaceBottomingBroken or worn coil springMalfunctioning shock absorberReplaceReplaceWheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating...