TSB_TRA083_R1

GROUP
TRA
NUMBER
083 (Rev 1, 08/24/2021)
MODEL
2016-2020MY
Multiple Models
with 7-Speed DCT
DATE
December 2020
TECHNICAL SERVICE BULLETIN
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
SUBJECT:
 NOTICE
This bulletin has been revised to include additional information. New/revised
sections of this bulletin are indicated by a black bar in the margin area.
This bulletin provides the procedure to replace Dual Clutch Assembly and upgrade the TCU on
some 2016-2020MY Kia vehicles listed in the table below, equipped with the 7 Speed Dual
Clutch Transmission (DCT), which might exhibit clutch judder when accelerating from a stop. If
the vehicle body vibrates without the steering wheel shuddering when performing creep driving
test (driving the vehicle up to 3mph), the vehicle is exhibiting clutch judder. The creep test can
be conducted by driving at a speed slower than 5 mph after releasing the brake. In order to
remedy clutch judder, the Dual Clutch Assembly must be replaced and the TCU will need to be
upgraded.
Model
Production Date
Optima 1.6L T-GDI (JFa)
08/28/2015 - 06/01/2020
Soul 1.6L T-GDI (PS)
08/08/2016 - 10/27/2016
Soul 1.6L T-GDI (SK3)
11/24/2018 - 04/02/2020
Forte 1.6L T-GDI (YDm)
09/10/2016 - 12/28/2016
Forte (BDm)
07/09/2018 - 08/03/2020
 NOTICE
For Optima (JFa) ONLY, confirm that the latest S/W is
installed PRIOR to performing this bulletin (TRA083),
refer to TRA098 for latest software.
File Under: 
Circulate To:
X General Manager

X Service Advisors

X Technicians

X Service Manager

X Parts Manager

X Body Shop Manager 
X Fleet Repair

Page 2 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
Clutch Judder Inspection:
 NOTICE
For Optima (JFa) ONLY, confirm that the latest S/W is installed PRIOR to performing
the procedures outlined in this bulletin (TRA083), refer to TRA098 for latest software.
1.
Park vehicle on a flat surface.
2.
Using KDS, select ‘S/W Management’
from the Home screen.
3.
In the ‘Systems’ tab, under ‘Double
Clutch Transmission’, select ‘DCT
Clutch Judder Measurement’.
4a. Confirm the ‘Enable Condition’ list.
4b. Select ‘OK’.
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 3 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
5a. Under ‘Test preparation’ follow the
preparation instructions on KDS.
5b. Diagnosis equipment position: Place
the KDS on the right passenger floor as
shown.
5c. Select ‘OK’.
6a. Under ‘Condition test’, satisfy the listed
conditions on KDS.
6b. Select ‘OK’.
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 4 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
7a. Under ‘Judder measurement’ review
the ‘Procedures’ outlined on KDS to
measure DCT judder and follow the
instructions on the screen to start creep
driving.
7b. Release the brake and let the vehicle
move forward without the pressing the
pedal.
Note: Performed a total of five (5x) times.
8.
After completing the measurement test,
apply the brake as instructed on KDS
screen.
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 5 of 11
SUBJECT:
9.
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
Under ‘Test completed’, take the
appropriate action based on the ‘Result’
as follows:
1) If the result is "Good": No further
action is required.
2) Select ‘OK’ to complete.
3) If the result is “DC Inspection
required”, replace the Double Clutch
Set by referring to the DCT
Replacement Procedure outlined on
page 6.
Note: Double Clutch (DC)
4) Select ‘OK’ to complete.
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 6 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
Replacement Procedure:
1. Remove the DCT assembly by referring
to “DCT (Dual Clutch Transmission)
System
→
DCT
(Dual
Clutch
Transmission) System → DCT (Dual
Clutch
Transmission)
→
Repair
procedures” chapter in the applicable
Shop manual on KGIS.
Or refer to Dual Clutch Assembly video.
2.
Place the DCT clutch housing facing up
as shown.
 NOTICE
When putting the DCT assembly
down, be careful to not damage
the clutch actuator motor
connector (A).
3.
Remove the retaining ring (B) using snap
ring pliers.
 NOTICE
A
B
DO NOT re-use the snap ring.
Replace with a new part.
4.
Remove the spline hub (C).
C
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 7 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
5a. Remove the retaining ring (D) using snap
ring pliers.
D
 NOTICE
Be careful not to damage the
rubber seal of the dual clutch
support bearing when removing
the snap ring. DO NOT re-use
the snap ring; replace.
5b. (OPTIONAL) If the retaining snap ring is
stuck, insert the SST 09430 2A240 (E)
and hit the top of the SST with a rubber
hammer to release the stuck snap ring.
6.
7.
Locate the 3 points shown on the dual
clutch assembly (F) and install the SST
09430 C1180 (G) between the clutch
connecting plate and the pressure plate
where shown.
E
G
F
Turn the top bolt head clockwise on the
SST to pull and release the dual clutch
set from the DCT.
 NOTICE
Be careful not to drop the dual
clutch assembly when removing
from DCT.
TSB: TRA083 (Rev 1) Multiple Models December 2020
Page 8 of 11
SUBJECT:
8.
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
Remove any foreign substance from the
DCT input shaft (H). Clean using a soft
brush and non-lubricant solution. DO
NOT use sandpaper, wire brush or
WD40 type cleaning materials.
H
9.
Apply 0.15 – 0.25g of MCLUBE MoS2400 grease evenly around the upper and
lower input shaft circumferences, as wide
as 10mm from the spline end area where
shown.
10mm
10mm
 NOTICE
DO NOT use more than the
recommended
amount
of
grease. Excess grease can
spread and cause clutch to slip.
10. Before proceeding to the next step, refer
to TSB TRA085 “DCT Actuator Rod
Length Adjustment” procedure. The
Clutch Actuator Adjustment Jig SST
09430 C1302 shown will be required.
SST 09430 C1302
11. Install the new dual clutch assembly into
the DCT housing using SST 09430
C1180 (I) in the reverse order of
removal. Be sure to align the input shaft
properly. DO NOT press dual clutch
assembly as damage may occur.
 NOTICE
Be careful not to drop the dual
clutch assembly when removing
from DCT.
TSB: TRA083 (Rev 1) Multiple Models December 2020
I
Page 9 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
12. Insert the SST 09430 2A240 over the
support bearing as shown.
13. Secure the SST 09430 2A240 (J) onto
the clutch housing as shown and then
turn the bolt head clockwise until the dual
clutch assembly is secured.
J
14. Install and secure the new retaining ring
(D) using snap ring pliers.
 NOTICE
D
The retaining must be able to
move freely left to right.
15. Install the spline hub (C).
C
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Page 10 of 11
SUBJECT:
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
16. Install the new retaining ring (B) using
snap ring pliers.
17. Install all of the parts in the reverse order
of removal.
18. Using KDS, clear any DTCs stored.
19. Perform the DCT Learning Function
procedure using KDS.
20. Follow the applicable TCU Logic
Optimization Procedure from TSB
TRA078 (pages 3-6 only) to upgrade the
TCU logic. Use the applicable Op Code
from this bulletin, page 11.
TSB: TRA083 (Rev 1) Multiple Models December 2020
B
Page 11 of 11
7-SPEED DCT JUDDER INSPECTION AND
DUAL CLUTCH ASSEMBLY REPLACEMENT
SUBJECT:
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Optima (JFa) 1.6L T-GDI GAMMA
August 28, 2015 – June 1, 2020
Soul (PS) 1.6L T-GDI GAMMA
August 8, 2016 – October 27, 2016
Soul (SK3) 1.6L T-GDI
November 15, 2018 – April 02, 2020
Forte (YDm) 1.6L T-GDI GAMMA
September 10, 2016 – December 28, 2016
Forte (BDm)
July 9, 2018 – August 08, 2020
REQUIRED TOOL:
Tool Name
Part Number
Dual Clutch Installer
09430 2A240
Dual Clutch Remover
09430 C1180
Figure
Note: Refer to TSB TRA085 for additional tools required.
REQUIRED PART:
Part Name
Part Number
Figure
Qty.
Dual Clutch Assembly
41200 2D220FFF
1
Dual Clutch Snap Ring
41068 2D000FFF
2
WARRANTY INFORMATION:
N Code: V81 C Code: ZZ6
Claim
Type
Model
W
ALL
Causal
P/N
Qty.
Repair
Description
Labor Op
Code
0
Dual Clutch Judder
Inspection (KDS)
41200F19
PS
SK3
W
JFa
BDm
YDm
41200F14
41200
2D220
0
Dual Clutch
Assembly
Replacement and
Dual Clutch Judder
Inspection (KDS)
41200F13
41200F15
41200F10
41200F07
Op
Time
0.3
M/H
3.5
M/H
3.4
M/H
3.7
M/H
3.2
M/H
4.0
M/H
Replacement
P/N
Qty.
N/A
0
41200
2D220FFF
1
and
41068
2D000FFF
2
TSB: TRA083 (Rev 1) Multiple Models December 2020