20-01-021H-1

GROUP
NUMBER
CAMPAIGN
DATE
Technical Service Bulletin
20-01-021H-1
MODEL(S)
May, 2020
Kona (OS), Elantra Sport (AD),
Elantra GT (PD)
DCT REPLACEMENT: TRANSFERRABLE PARTS
(SERVICE CAMPAIGN T4Q)
SUBJECT:
This TSB replaces 20-01-021H by updating the description section.
 IMPORTANT
*** Dealer Stock and Retail Vehicles ***
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America's Vehicle
Information Screen (VIS) via WEBDCS to identify open Campaigns.
Description: For certain Elantra GT (PD), Elantra Sport (AD), or Kona (OS) vehicles, replace the
Dual Clutch Transmission (DCT) using the applicable QQH part number (see Parts Information), and
transfer parts from the original DCT onto the replacement DCT. Refer to the figure below for
transferred parts:
Original DCT
5
4
2
1
Replacement DCT
3
1. Dual Clutch
2. Clutch Engagement Bearing
3. Clutch Engagement Fork
6
4. Clutch Actuator
5. Gear Actuator and Wiring
6. 4WD (If applicable)
Applicable Vehicles: Certain 19MY Elantra GT (PD), Elantra Sport (AD) and Kona (OS) vehicles
Special Service Tools
SPECIAL SERVICE
PART NUMBER
TOOL
DESCRIPTION
Double Clutch
Remover
09430-C1180
Used to remove the
double clutch from the
transmission
Double Clutch
Installer
09430-2A240
Used to install the double clutch into the
transmission
PHOTO
The Special Service Tools can be ordered through Bosch at (866) 539-4248.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
DCT REPLACEMENT: TRANSFERRABLE PARTS
SUBJECT:
Parts Information:
MODEL
PART NUMBER
Included with
Transmission
DESCRIPTION
REMARK
Outer Clutch Snap Ring
Inner Clutch Snap Ring
All Models
Grease
5g
Elantra GT (PD)
4300D2-D077QQH
Transmission
Elantra Sport (AD)
Kona (OS) 4WD
4300M2-D142QQH
Kona (OS) 2WD
4300D2-D132QQH
Transmission
Warranty Information:
MODEL
OP CODE
OPERATION
Kona (OS)
2WD
90C046R0
Kona (OS)
4WD
90C046R1 DCT REPLACEMENT
Elantra
Sport (AD)
90C046R2 DCT REPLACEMENT
DCT REPLACEMENT
OP TIME
CAUSAL
PART
NATURE
CODE
CAUSE
CODE
43370-2D150
T43
ZZ1
3.2 M/H
4.6 M/H
3.2 M/H
Elantra GT
90C046R4 DCT REPLACEMENT 3.5 M/H
(PD)
Note 1: Submit claim on Campaign Claim Entry Screen.
Note 2: If a part is found in need of replacement while performing Service Campaign T4Q and the
affected part is still under warranty, submit a separate claim using the same Repair Order. If the
affected part is out of warranty, submit a Prior Approval Request for goodwill consideration prior to the
repair.
NOTICE
Please consult the applicable vehicle shop manual prior, during, and after performing steps
instructed in this bulletin to ensure best results.
CAUTION
To avoid damage, reuse the dual clutch, clutch engagement bearing, clutch engagement fork,
clutch actuator, and gear actuator and wiring. If applicable, also reuse the 4WD drive.
TSB #: 20-01-021H-1
Page 2 of 11
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SUBJECT:
DCT REPLACEMENT: TRANSFERRABLE PARTS
Service Procedure:
A) DCT Removal
1.
Using the applicable vehicle shop
manual, carefully remove the DCT from
the vehicle.
The correct section can be located
below:
2.
1
The following parts will be removed
from the DCT:
1)
2)
3)
4)
5)
3
Gear Actuator and Wiring
Dual Clutch
Clutch Actuator
Clutch Engagement Bearing
Clutch Engagement Fork
2
4
5
NOTICE
6
6) If applicable, remove and
transfer the 4WD drive. Use the
applicable shop manual for
removal and transfer procedure.
NOTICE
Place parts aside for reuse.
3.
Remove the actuator bolts, and remove
the gear actuator and wiring (G).
NOTICE
Save all bolts for reuse.
TSB #: 20-01-021H-1
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DCT REPLACEMENT: TRANSFERRABLE PARTS
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4.
Remove both the inner snap ring and
outer ring.
NOTICE
New snap rings have been supplied.
5.
To prevent damage, remove the dual
clutch using the double clutch remover.
Double Clutch
Remover
6.
Remove the mounting bolts and remove
the clutch actuator (F).
NOTICE
Save all bolts for reuse.
7.
Remove both engagement bearings (A)
and (B).
TSB #: 20-01-021H-1
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8.
DCT REPLACEMENT: TRANSFERRABLE PARTS
Remove the fork mounting bolts and
bearing mounting bolts.
BLUE MARK*
(Bearing
sleeve bolt)
RED MARK*
(Fork bolt)
NOTICE
Save all bolts for reuse.
9.
Remove the clutch engagement fork (C)
and engagement bearing sleeve (D).
B)B) DCT Installation
1.
The following removed parts will be
installed into the new DCT:
1)
2)
3)
4)
5)
2.
5
Clutch Engagement Fork
Clutch Engagement Bearing
Clutch Actuator
Dual Clutch
Gear Actuator and Wiring
4
=
3
2
1
4
Remove any grease from the clutch fork
using a towel.
TSB #: 20-01-021H-1
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DCT REPLACEMENT: TRANSFERRABLE PARTS
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3.
Apply approximately 0.5g of supplied
grease evenly to all six clutch fork
areas.
4.
Remove any grease on both input
spline shafts using a towel.
5.
Apply approximately 0.2g of supplied
grease to both input shaft spline areas.
See reference picture for location.
CAUTION
Prevent over application of grease.
TSB #: 20-01-021H-1
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6.
DCT REPLACEMENT: TRANSFERRABLE PARTS
Install the clutch fork (C) and bearing
sleeve (D) along with the fork and
bearing sleeve bolts according to the
applicable vehicle shop manual
instructions.
The correct section can be located
below:
Torque specifications for the bearing
sleeve bolts and fork bolts are listed
below:
BEARING
SLEEVE
(Blue)
FORK
(Red)
NOTICE
Align clutch fork with plastic bearing
guide direction. See reference
diagram to the right.
CAUTION
Verify that the plastic bearing stopper
sits flush within the engagement
bearing sleeve. See reference photo
to the right.
TSB #: 20-01-021H-1
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SUBJECT:
DCT REPLACEMENT: TRANSFERRABLE PARTS
7.
Install both engagement bearings (A)
and (B).
8.
Align the clutch actuator to the dowel
pins positions as displayed in the
reference diagram to the right.
9.
Install the clutch actuator (F) and
reinstall the mounting bolts. Torque
specifications are listed below:
10.
Install clutch actuator cover (E). Torque
specifications for the bolts are listed
below:
E
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11.
DCT REPLACEMENT: TRANSFERRABLE PARTS
Carefully install the dual clutch using
the double clutch installer.
Place the cup portion of the double
clutch installer over the transmission
input shaft.
Double Clutch
Installer
Base
Cup
Ring
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DCT REPLACEMENT: TRANSFERRABLE PARTS
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12.
Install the supplied snap rings during
the dual clutch installation.
Inner
Snap Ring
Outer
Snap Ring
CAUTION
If snap rings are not installed
correctly, the transmission will not
shift correctly!
Outer Snap
Ring
Inner Snap Ring
13.
Verify all snap ring hook areas are
properly installed around entire surface
area.
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14.
DCT REPLACEMENT: TRANSFERRABLE PARTS
Install the gear actuator and wiring (G)
HORIZONTALLY and install the
actuator bolts. Torque specifications are
listed below:
BOLT (A)
BOLT (B)
CAUTION
Gear actuator must be installed in
neutral position.
15.
Reinstall DCT in vehicle.
See shop manual for proper installation:
CAUTION
Inspect transmission oil levels after
installation. Add new oil if
transmission oil levels are low.
16.
Use the GDS to perform the DCT
relearn.
17.
Service procedure is now complete.
TSB #: 20-01-021H-1
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