Hyundai Tucson: DCT (Dual Clutch Transmission) System (SBW)- Removal

Components

1. DCT (Dual Clutch Transmission) assembly
2. DCT support bracket
3. Roll rod support bracket

Removal

1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.  Remove the air cleaner assembly and air duct.

(Refer to Engine Mechanical System - "Air cleaner")

3. Remove the ECM.

(Refer to Engine Control / Fuel System - "Engine Control Module (ECM)")

4. Remove the battery and battery tray.

(Refer to Engine Electrical System - "Battery")

5. Disconnect the wiring bracket (A).

6. Disconnect the gear actuator connector (A).

7. Loosen the mounting bolts (A) and then remove the wiring bracket.

Tightening torque : 9.8-11.8 N.m (1.0-1.2 kgf.m. 7.2-8.7 lb-ft)

8. Disconnect the connectors in the illustration below

1. TCM connector
2. Input speed sensor connector
3. Electronic shift actuator connector
4. Position sensor connector

9. Loosen the ground mounting bolt (A).

Tightening torque : 9.8-11.8 N.m (1.0-1.2 kgf.m. 7.2-8.7 lb-ft)

10. Loosen the starter mounting bolts (A) and the transmission upper mounting bolts (B).

Tightening torque :

(A): 49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)

(B): 42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)

11. Assemble the engine support fixture use a (Beam SST No.: 09200 - 3N000. Adapter SST No.: 09200-4X000, Engine support fixture (supporter) SST No.: 09200-2S200. Engine support fixture (front) SST No.: 09200-L1200.
12. Using the engine support fixture (A), hold the engine and transaxle assembly safely.

13. Remove the front wheel guard.

(Refer to Body (Interior and Exterior) - "Front Wheel Guard")

14. Loosen the transmission bracket support mounting bolts (A).

Tightening torque : 107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

15. Loosen the bolts and then removing the transmission bracket (A).

Tightening torque : 58.8 - 78.5 N.m (6.0 - 8.0 kgf.m. 43.4 - 57.9 lb-ft)

16. Remove the engine room under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")

17. Loosen the ground mounting bolt (A).

Tightening torque : 9.8-11.8 N.m (1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

18. Loosen the mounting bolts (A) and then remove the wiring bracket.

Tightening torque : 9.8-11.8 N.m (1.0-1.2 kgf.m, 7.2-8.7 lb-ft)

19. Remove the front sub frame

(Refer to Suspentiou System - "Frout Sub Frame")

20. Loosen the bolts and then removing the roll rod support bracket (A).

Tightening torque : 49.0 - 68.6 N.m (5.0 - 7.0 kgf.m. 36.2 - 50.6 lb-ft)

21. Remove the driveshaft assembly.

(Refer to Driveshaft and Axle - "Front Driveshaft")

22. In case of 4WD vehicle, remove the transfer assembly.

(Refer to 4 Wheel Drive (4WD) System - "Front Wheel Transfer Assembly")

23. Support the transmission safely by using the jack.
24. Loosen the transmission lower mounting bolts (A, B).

Tightening torque :

(A): 42.2 - 53.9 N.m (4.3 - 5.5 kgf.m. 31.1 - 39.8 lb-ft)

(B): 42.2 - 48.1 N.m (4.3 - 4.9 kgf.m, 31.1 - 35.4 lb-ft)

25. After separating the transmission from the engine, remove the transmission by lowering the jack slowly.

WARNING

Be careful not to damage other nearby systems or paits when removing the transmission assembly.

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