Hyundai Ioniq: Gear Actuator Assembly / Repair procedures

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

Removal
   
•
Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
   
•
Be sure to shift gear to Neutral by “Actuation Test” procedure using the GDS before removing gear actuator assembly.
   
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
1.
Shut off the High Voltage circuit.
(Refer to General Information - "High Voltage Shutoff Procedure")
2.
Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3.
Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster.
(Refer to Hybrid Motor System - "Coolant")
4.
Remove the HPCU (Hybrid Power Control Unit).
(Refer to Hybrid Control System - "Hybrid Power Control Unit (HPCU)")
5.
Remove the ECM (Engine Control Module) and TCM (Transmssion Control Module).
(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
(Refer to Dual Clutch Control System - "DCT Control Module (TCM)")
6.
Remove the HPCU (Hybrid Power Control Unit) tray.
(Refer to Hybrid Control System - "Hybrid Power Control Unit (HPCU)")
7.
Disconnect the gear actuator motor connector (A) and solenoid connector (B).

8.
Remove the gear actuator assembly after loosening bolts (A-3ea, B-2ea).
Tightening torque :
(A) : 19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
(B) : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Installation
1.
Install in the reverse order of removal.
   
•
Check the details below before installing the gear actuator assembly.
1)
Check that the gear actuator is placed in the "neutral" state.
2)
Check the assembled state of the O-rings (A).

3)
Apply gear oil to the surface of O- rings.
4)
Check the assembled state of the dowel pins (A).

•
Perform the gear actuator learning procedure using the GDS after replacing the gear actuator assembly.

    Schematic diagrams

    C..

    Input shaft speed sensor 1

    ..

    Other information:

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


    S..

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