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Tips for CLUTCHES, Clutch Kit Valeo Dual Dry Clutch Mandatory Tooling Requirements and how it is implemented | Valeo Service

Technical Service Bulletin for CLUTCHES, Clutch Kit, 855101 - Valeo Service

Valeo Dual Dry Clutch Mandatory Tooling Requirements

The Valeo Dual Dry Clutch (DDC) assembly installed in Hyundai and Kia applications that utilise the DCT-7 transmission requires specific and mandatory tooling in order to facilitate a repair. Each item of tooling will be required in order to safely and correctly perform the full repair process, and to prevent potential damage to the gearbox bell housing, input shaft splines and the DDC assembly. The required actuator calibration will also ensure correct clutch operation preventing juddering, poor gear selection and shifting.

Installer Tool PN DDCT-01

Correct installation of the DDC kit must be performed&nbsp; 
with the installer tool and associated adapters. 
This enables a uniform even pressure to the DDC centre 
bearing, ensuring the assembly is pressed fully onto the&nbsp; 
gearbox input shaft to the correct position 
&nbsp;

Removal Tool PN DDCT-02

 
Due to minimal space around the DDC assembly within the 
bell housing, the removal tool will be required to safely&nbsp; 
and correctly extract the DDC assembly from its seated 
position on the gearbox input shaft, preventing possible 
damage to both bell housing and input shaft and / or splines 
&nbsp;

Actuator Adjustment Rig &amp; Adjusting Tool PN DDCT-03 / DDCT-4

 
Calibration of the actuator must be completed to ensure 
correct clutch operation. The length of the actuator cylinder 
rods must be measured and reset prior to the installation of&nbsp; 
the actuator, and MUST be set to the specific dimension, by use 
of the rig and adjusting tool 
&nbsp;

Valeo Service have received several returns of Dual Dry Clutches and after carrying out full investigations on the parts the correct tooling was not used during the repair. The clutches were not seated correctly due to uniform pressure when using the installer tool not being adhered to. It is therefore imperative that the correct tooling is used during the repair procedure. Below you can see images of the damage that can occur when not using the correct tooling.