2021-2022 Hyundai Elantra Kona DCT Shift Shock TSB

Important Warnings for Owners

Hyundai has issued specific instructions regarding this service campaign:

• Dealer Action Required: Dealers are mandated to perform this Service Campaign on all affected vehicles before customer retail delivery and whenever an affected vehicle is in the shop for any maintenance or repair. This means if your vehicle is covered, the repair should be completed without you having to specifically request it during a service visit.
• Snap Ring Reuse: Technicians are explicitly warned not to reuse existing snap rings when reinstalling the Double Clutch into the transmission, as they can deform during removal.
• Oil Seal Replacement: The repair requires using a newly supplied oil seal during reassembly, and the oil seal lip must not be contaminated with lithium grease.
• Clutch Engagement Fork: It is critical to ensure the clutch engagement fork is seated correctly to prevent clutch actuator rod position deviation during reassembly.
• New Snap Ring Installation: When installing the new snap ring, it must be fully seated and able to rotate left and right freely to ensure proper function.

Symptoms

Owners of affected 2021-2022 Hyundai Elantra and Kona vehicles may notice abnormal shifting behavior. Specifically, the vehicle may exhibit a 'shift shock' sensation during 1-2 or 2-1 gear changes in the 7-speed Double Clutch Transmission (DCT).

Diagnosis / Trigger Conditions

To diagnose the Hyundai Elantra shift shock or Kona shift shock, technicians perform a specific test drive procedure:

1. Vehicle Type Check: For 2WD vehicles, shift shock inspection is unnecessary, and the technician proceeds directly to snap ring replacement. For AWD vehicles, a test drive is required.
2. Test Drive Preparation: The vehicle is driven on a suitable flat road.
3. Downshift Shock Inspection: The accelerator is depressed to 30% to slowly accelerate to 16 MPH. Brakes are then gently applied to decelerate to 6 MPH, and the technician inspects for shift shock during the 2-1 downshift.
4. Upshift Shock Inspection: From a stop, the accelerator is depressed to 50-70%, and the technician inspects for shift shock during the 1-2 upshift.
5. Repeatability: Steps 3-5 are repeated 3-4 times to confirm the presence of shift shock.

If shift shock occurs more than once, the input shaft snap ring replacement procedure is initiated.

Repair Procedure Summary

The repair for the Hyundai Elantra shift shock involves removing the Dual Clutch Transmission (DCT) and replacing the input shaft snap ring. The general steps are:

1. Transmission Removal: The Dual-Clutch Transmission is removed from the vehicle following standard shop manual procedures.
2. Disassembly: The retaining ring, splined hub, and existing snap ring are removed. The clutch release bearing, clutch engagement fork, and bearing sleeve are also removed.
3. Oil Seal Removal: The input shaft oil seal is carefully removed using a special tool.
4. Old Snap Ring Removal: The old input shaft snap ring is removed from the shaft using snap ring pliers, a flat blade screwdriver, and a 90° pick.
5. Snap Ring Sizing: The marked size of the original snap ring is checked. A new snap ring, two increments smaller (0.06mm smaller) than the original, is selected from the service kit. For example, an original snap ring marked '04' (2.04mm) is replaced with a '98' (1.98mm).
6. New Snap Ring Installation: The new snap ring is slid over the shaft and gently tapped into place using a seal installer. It must be fully seated and rotatable.
7. New Oil Seal Installation: A new input shaft oil seal is installed, ensuring the yellow color face is down and the seal is flush with the transmission assembly. The oil seal lip must not be contaminated.
8. Reassembly: The clutch engagement fork, clutch release bearing sleeve, and clutch release bearing are reinstalled. The clutch engagement fork must be correctly seated.
9. Dual-Clutch Installation: The Double-Clutch is installed back into the transmission using a special installer tool, ensuring it is fully seated and the snap ring groove is exposed.
10. Final Assembly: The Dual-Clutch Transmission is reinstalled into the vehicle.
11. Verification: A test drive is performed to confirm that shift shock is no longer present.

Required Tools and Parts

To address the Hyundai Elantra shift shock issue, specific parts and special service tools are required:

Parts Information:

• Service Kit (Kona (OS), Elantra (CN7) 7-Speed DCT): 43239-2A100QQH
  • Retaining Ring: 41126-2D100
  • Double Clutch Snap Ring: 41068-2D000
  • Input Shaft Oil Seal: 43134-2A010
  • Snap Ring (various sizes): 43239-2A195, 43239-2A198, 43239-2A201, 43239-2A204

Special Service Tools:

• Double Clutch Remover: 09430-C1180
• Double Clutch Installer: 09430-2A240
• Oil Seal Installer Jig: 09431-IB000FFH
• Leverage/shaft style oil seal puller (e.g., Lisle 58430 Shaft Type Seal Puller or equivalent)

Warranty Information

This service is covered under Service Campaign T7E. The relevant warranty information for technicians includes:

• Operation Codes (OP CODES):
  • 10D124R0: Shift Shock Inspection (0.3 M/H for AWD)
  • 10D124R1: Shift Shock Inspection + Snap Ring Replacement (3.8 M/H for AWD)
  • 10D124R2: Snap Ring Replacement (3.5 M/H for 2WD)
  • 10D124R3: Snap Ring Replacement (3.6 M/H for 2WD Elantra)
• Causal Part: 43239-2A100QQH
• Nature Code: T41
• Cause Code: ZZ1

Claims should be submitted via the Campaign Claim Entry Screen. If additional parts not covered by Campaign T7E are needed and are under warranty, a separate claim can be submitted. For out-of-warranty parts, a Prior Approval Request for goodwill consideration may be required.

Owner Action

If you own a 2021-2022 Hyundai Elantra or Kona and experience abnormal shifting or Hyundai Elantra shift shock, you should contact your authorized Hyundai dealer. This issue is addressed under Service Campaign T7E, meaning the inspection and repair should be performed free of charge. Dealers are instructed to perform this service proactively during any maintenance visit or prior to vehicle delivery.

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Source: NHTSA ID 10207807