21-AT-014H

GROUP
NUMBER
AUTOMATIC
TRANSMISSION
Technical Service Bulletin
SUBJECT:
21-AT-014H
DATE
MODEL(S)
TUCSON (TL) 1.6T,
SONATA (LFa) 1.6T
August, 2021
DUAL CLUTCH TRANSMISSION JUDDER DETECTION AND TCU
SOFTWARE UPDATE
This TSB supersedes 20-AT-021H by putting Tucson and Sonata models on their own TSB and
provides a revised GDS-M software update for low speed judder.
Description: Certain vehicles (listed below) equipped with 7-speed Double Clutch Transmissions
(DCT) may exhibit abnormal vibration at low speeds. This bulletin outlines the procedures for
diagnosing clutch judder, updating the Transmission Control Unit (TCU) with revised logic, and/or
replacing the Double Clutch.
Applicable Vehicles: 2016-2018 Tucson (TL) 1.6L Turbo
2015-2018 Sonata (LFa) 1.6L Turbo
Parts Information:
MODEL
Tucson (TL) 1.6L Turbo
Sonata (LFa) 1.6L Turbo
DTC
PART
PNC
PART NUMBER
Double Clutch
41200C
41200-2D220
Snap Ring
44167G
41068-2D000
Warranty Information:
MODEL
OP CODE
OPERATION
OP TIME
CAUSAL
PART
Tucson (TL)
1.6L Turbo
Sonata (LFa)
1.6L Turbo
41200F18
GDS-M Judder
Inspection Only
0.3 M/H
41200-2D101
Tucson (TL)
1.6L Turbo
Sonata (LFa)
1.6L Turbo
41200F19
GDS-M Judder
Inspection + TCU
Upgrade +
GDS-M Judder
Reinspection
0.8 M/H
41200-2D101
Tucson (TL)
1.6L Turbo
41200F20
3.8 M/H
41200-2D101
Sonata (LFa)
1.6L Turbo
41200F21
4.4 M/H
41200-2D101
Clutch Judder
Inspection +
Double Clutch
Replacement +
TCU Upgrade
NATURE
CODE
CAUSE
CODE
V81
ZZ3
Note: Normal Warranty Applies
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
SUBJECT:
Special Service Tool Information:
SPECIAL SERVICE TOOL PART NUMBER
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
Actuator Fixing Jig & Motor
Shaft Reset Tool
09430-C1302
Used to measure and reset
the double clutch actuator
Clutch Abrasion
Compensation
09430-C1300
Clutch actuator adjustment
tool
PHOTO
(If additional SST is needed, replacement parts can be ordered from Bosch at (866) 539-4248.)
GDS-M Information: System Selection: TCU
Event #
Model
Description
683
TL
1.6T 7DCT - TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
684
2015-2017MY LFa
1.6T 7DCT - TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
685
2018-2019MY LFa
1.6T 7DCT - TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
TCU Manual Mode Password Information Table:
Vehicle Type
Menu
Password
LFa 1.6T-GDI (7-DCT) TCU 95441-2D001
1002
LFa 1.6T-GDI (7-DCT) TCU 95441-2D002
1202
LFa 1.6T-GDI (7DCT) TCU 95441-2D040
1.6T
0402
TL 1.6T(7DCT) TCU 95440-2D720
0272
TL 1.6T(7DCT) TCU 95440-2D721
1272
NOTICE


If judder is detected while testing, be sure to upgrade TCU logic and retest before
replacing the Dual Clutch Transmission.
Attach the Judder inspection result when replacing the Double clutch.
TSB #: 21-AT-014H
Page 2 of 16
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
SUBJECT:
ROM ID Information Table:
MODEL
SYSTEM
PART NUMBER
OLD
NEW
OLD
NEW
DTLOT16NS0
DTLOT16NS1
DTLOT16NS2
DTLOT16NS3
DTLOT16NS4
DTLOT16NS5
DTLOT16NS6
DTLOT16NS7
DTLOT16NS8
DTLOT16N30
DTLOT16N70
95441-2D721
DTLOT16NS9
DTLOT16NSA
DTLOT16NSB
DTLOT16NSC
DTLOT16NSD
DTLOT16N31
DTLOT16N71
95441-2D000
95441-2D001
DLF0T16NS7
DLF0T16NS8
DLF0T16NS9
DLF0T16NSA
DLF0T16NSB
DLF0T16NSC
DLF0T16N32
DLF0T16N72
95441-2D002
95441-2D002
DLF0T16NSD
DLF0T16N33
DLF0T16N73
95441-2D040
DLF0T16NL0
DLF0T16NL1
DLF0T16NL2
DLF0T16NL3
DLF0T16NL4
DLF0T16NL5
DLF0T16N34
DLF0T16N74
95441-2D720
Tucson
(TL)
Sonata
(LFa)
95440-2D721
TCM
TCM
ROM ID
95441-2D040
Updated F850 Clutch Material Identification:
MODEL
2016-2017 Tucson (TL) 1.6L Turbo
2015-2017 Sonata (LFa) 1.6L Turbo
PREVIOUS CLUTCH PART
NUMBER (F833DS)
NEW CLUTCH PART NUMBER
(F850)
41200-2D101
41200-2D220
TSB #: 21-AT-014H
Page 3 of 16
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SUBJECT:
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
Troubleshoot Flow Diagram:
NG
A. GDS-M Clutch Judder Inspection
1. Using the GDS-M-M, enter the vehicle
information, select S/W Management, and
then select DCT Clutch Judder
Measurement.
TSB #: 21-AT-014H
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
2.
Follow the information specified in Enable
Condition and select OK.
3.
Follow the instructions on the Test Preparation
screen to prepare the vehicle for DCT Judder
Measurement.
Remove the passenger side floor mat and place
the GDS-M flat and straight on the passenger
floor.
Select OK.
TSB #: 21-AT-014H
Page 5 of 16
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
4.
Verify that all vehicle conditions are PASS and
select OK.
5.
Follow the instructions from the Judder
Measurement screen to perform the judder
clutch inspection.
The inspection is complete when the 5Times
reading appears.
NOTICE
Do not brake or operate the
accelerator during the inspection.
6.
After the measurement is complete, apply the
brakes for 4-5 seconds.
TSB #: 21-AT-014H
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
7.
If the result is “PASS, No Judder Detected”,
the service procedure is complete.
8.
If the result is, “Judder Detected, Replace
Double Clutch,” reflash TCU with latest update
by referring to section B. Automatic TCU
Upgrade Procedure.
NOTICE
Update the TCU with the latest software and retest
before replacing the Double Clutch.
9.
After updating the TCU, retest for Judder
following GDS-M Clutch Judder Inspection
steps 1-8, starting on Pages 4-7.
If the result is still “Judder Detected, Replace
Double Clutch,” replace the double clutch
assembly by referring to section D. Clutch
Replacement Procedure on page 13.
TSB #: 21-AT-014H
Page 7 of 16
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SUBJECT:
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
B. Automatic TCU Upgrade Procedure
1.
Verify that the vehicle battery has
enough battery to perform the
software upgrade.
2.
Turn off all accessories and lamps.
3.
Perform the upgrade with the ignition
switch in the ON position.
4.
Do not disconnect any cables
connected to the vehicle or scan tool
during upgrade.
5.
Do not start the engine during the
upgrade.
6.
Do not turn off the ignition switch
during upgrade.
7.
Connect the VCI-II into the vehicle's
DLC connector.
8.
Enter the vehicle information and
select ECU Upgrade.
9.
Select Auto Mode. GDS-M will read the current vehicle ROM ID and check for the newest
upgrade event.
TSB #: 21-AT-014H
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
SUBJECT:
10.
Select the upgrade event.
10-1) 683.TL 1.6T(7DCT) -TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
10-2) 684.LFa 1.6T(7DCT) -TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
10-3) 685.LFa PE 1.6T(7DCT) -TCU UPDATE FOR ANTI JUDDER LOGIC IMPROVEMENT
683.TL (All)
684. LFa (4/2014 – 1/2017)
685. LFa (8/2018 – 8/2019)
11. Ensure that battery voltage is at least 12 Volts before TCM upgrade. If battery voltage is
adequate, click OK to begin TCU upgrade.
!
WARNING
GDS-M Vehicle Battery Low Voltage Warning:
When the vehicle battery is lower than 12 volts, the GDS-M will trigger a Low Battery Voltage
Warning. If this Warning occurs,
A. Connect the battery to a fully charged battery jump pack or GR8 charger using “Power
Supply Mode” to continue the software update.
OR
B. Select “BACK” to exit the SW update. Then, start the engine and idle with the headlights
on for 20 minutes. Return to the SW update after charging the battery.
12. Upgrade (1/2) and (2/2) will begin. Upgrade progression will be visible on screen until
completion.
TSB #: 21-AT-014H
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13. After upgrade (2/2) is complete,



Turn the ignition key OFF for 10 seconds
Position key ON
Press OK to continue
14. Check for Diagnostic Trouble Codes in ALL menus and erase any DTC.
15. If applicable, erase the DTC in the BlueLink system according to TSB 12-BE-005-2.
16. Use GDS-M to perform the double clutch learning function.
17. Repeat step A. GDS Clutch Judder Inspection to confirm normal vehicle operation. If judder
inspection fails, proceed to step D. Double Clutch Replacement Procedure on Page 13.
C. Manual TCU Upgrade Procedure
NOTICE


!
Manually upgrading the TCU should only be performed when the automatic
upgrade fails
If automatic upgrade fails,
o Turn the ignition key OFF for 10 seconds.
o Position it into to the ON position to reset control unit before
performing the manual upgrade.
WARNING
GDS-M Vehicle Battery Low Voltage Warning:
When the vehicle battery is lower than 12 volts, the GDS-M will trigger a Low Battery Voltage
Warning. If this Warning occurs,
A. Connect the battery to a fully charged battery jump pack or GR8 charger using “Power
Supply Mode” to continue the software update.
OR
B. Select “BACK” to exit the SW update. Then, start the engine and idle with the headlights
on for 20 minutes. Return to the SW update after charging the battery.
TSB #: 21-AT-014H
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SUBJECT:
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
1.
Turn off all accessories and lamps.
2.
Perform the upgrade with the ignition switch in
the ON position.
3.
Do not disconnect any cables connected to the
vehicle or scan tool during upgrade.
4.
Do not start the engine during the upgrade.
5.
Do not turn off the ignition switch during
upgrade.
6.
Connect the VCI-II into the vehicle's DLC
connector.
7.
Enter the vehicle information and select ECU
Upgrade.
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TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
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8.
Select Manual Mode, then select Upgrade
Event.
683. TL (All)
684. LFa (4/2014 – 1/2017)
685. LFa (8/2018 – 8/2019)
9. Enter the password provided on the TCU Manual Mode Password Information Table on Page 2.
10. Ensure that battery voltage is at least 12 Volts before TCM upgrade. If battery voltage is
adequate, click OK to begin TCU upgrade.
!
WARNING
GDS-M Vehicle Battery Low Voltage Warning:
When the vehicle battery is lower than 12 volts, the GDS-M will trigger a Low Battery Voltage
Warning. If this Warning occurs,
A. Connect the battery to a fully charged battery jump pack or GR8 charger using “Power
Supply Mode” to continue the software update.
OR
B. Select “BACK” to exit the SW update. Then, start the engine and idle with the headlights
on for 20 minutes. Return to the SW update after charging the battery.
TSB #: 21-AT-014H
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11. Upgrade (1/2) and (2/2) will begin and upgrade progression will be visible on the screen until
completion.
NOTICE
Do not make any selections until the upgrade is complete.
12. After upgrade (2/2) is complete,



Turn the ignition key OFF for 10 seconds
Position key ON
Press OK to continue
13. Check for Diagnostic Trouble Codes in ALL menus and erase any DTC.
14. If applicable, erase the DTC in the BlueLink system according to TSB 12-BE-005-2.
15. Use the GDS to perform the double clutch learning function.
16. Repeat step A. GDS Clutch Judder Inspection to confirm normal vehicle operation. If judder
inspection fails, proceed to step D. Double Clutch Replacement Procedure.
D. Double Clutch Replacement Procedure
1.
Remove the Dual-Clutch Transmission following
the shop manual procedure.
2.
Remove the retaining ring (A) (41126-2D100)
and the splined hub (B).
The snap ring can become deformed in the
removal process. Do not reuse the existing
snap rings when reinstalling the Double Clutch
into the transmission.
TSB #: 21-AT-014H
A
B
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3.
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
Remove the snap ring (C) (41068-2D000).
!
CAUTION
C
When installing the new snap ring,
make sure it is fully seated and
can be easily rotated left and right.
NOTICE
This operation requires special service
tools. Refer to SST Table on Page 2.
4.
Using the special service tool (SST 09430C1180), remove the double clutch from the
transmission assembly.
5.
Remove the 2 bolts (D) securing the fork cover.
Remove the 6 bolts (E) retaining the clutch
actuator assembly to the transmission.
E
D
E
6.
Remove the clutch actuator and place it on the
actuator fixing jig (SST 09430-C1302).
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7.
TCU SOFTWARE UPDATE AND DUAL CLUTCH REPLACEMENT
Follow the service shop manual procedure to
initialize the rod length for both odd and even
clutch actuator rods.
!
CAUTION
When installing a new DoubleClutch, the clutch actuator rod
length must be reset back to the
factory zero. If the rod length is
not adjusted correctly, the GDS-M
DCT relearn procedure will not
complete.
8.
Reinstall the clutch actuator in the order that it
was removed.
Torque: Fork Cover - 2.9-4.3 lb-ft (3.9-5.9
N.m)
Torque: Clutch Actuator - 14.5-19.5 lb-ft
(19.6-26.5 N.m)
9.
Install the new Double-Clutch using the special
service tool (SST 09430-2A240) to fully seat the
Double-Clutch.
NOTICE
(SST 09430-2A240) may appear different
than the reference photo.
10. Turn bolt (F) clockwise. When the force needed
to turn the bolt increases, the Double-Clutch is
fully seated.
TSB #: 21-AT-014H
F
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11. Verify the Double-Clutch is fully seated on the
input shafts. The snap ring groove (C) will be
fully exposed.
C
12. Install new snap ring (C), splined hub (B) and
retaining ring (A).
!
CAUTION
When installing the new snap ring,
make sure it is fully seated and
can be easily rotated left and right.
13.
Reinstall the Dual Clutch Transmission into the vehicle by following the service shop manual
procedure.
14.
The Service Procedure is now complete.
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