Hyundai dual-clutch transmission challenge#

Last tended 2026-02-03

NOTE: I also documented this in a Hyundai Forums post, where I included links to relevant parts, information sources, and tools.

I feared the worst when our 2017 Tucson AWD Limited one day began hesitating when upshifting -- most noticeable when shifting from 1st to 2nd -- followed by the unwelcomed glow of the check-engine light. By fearing the worst, I mean I feared a more-than-the-car's-worth cost to resolve the problem.

Attaching a scanner revealed it had a single diagnostic code stored: DTC P0805 - clutch position sensor fault. I felt a little better having a code that at least corresponded well with the symptom. I was also encouraged that no other codes or symptoms cropped up. Whenever I cleared the code and we drove again, we got just the same DTC P0805 and the same extreme hesitation upshifting from 1st to 2nd. Since the upshifting always -- eventually -- succeeded, I had good reason to take the code at face value: the problem was a sensor rather than the clutch or transmission. That was good news in my view; I could hope for a sensor remove/replace solution where the sensor was moderately priced and all labor could be DIY.

Quick note about the transmission

Though an automatic transmission, this is a far cry from the automatics of my youth. There is no torque converter to be found in this design. Instead, it is more accurately a six gear, two-clutch transmission, where one clutch is used for shifting into odd-numbered gears, and the other clutch is used for shifting into even gears. Equally important: electrical actuators are doing the gear changes plus the depressing and releasing of the clutches -- no human involved.

Understanding all of the above is important in light of the DTC P0805 code: clutch position sensor fault. Do you see the first issue? There are two clutches: has only one of the two sensors failed, and, if so, which one?

The compound challenge

This was a sort of onion-layers complex of challenges for auto-repair-hobbyist me. Roughly in order, here was the complex:

• Documentation/answers needed:
  • A Hyundia service manual for the transmission would obviously eliminate a lot of "learning by disassembly"
  • I need a source -- any source whatsover -- that indicated clearly where the problem sensor resided
    • was it a bolt-on, remove replace sensor?
    • was it integrated into another part?
• Tools needed:
  • Ability to trigger a "clutch touch point learning procedure": early in the online sleuthing I found that if you replaced any of the shifting components of this transmission, you needed a reasonably advanced diagnostic tool that could trigger a specific "re-learning function"
    • The ONLY diagnostic tool that very explicitly advertises itself as capable of this function is the "Hyundai GDS dealer-level diagnostic tool"
      • No-go problem: the price tag of this tool pushes me into "replace the whole car" territory
    • Least expensive tool for the task?
      • This was my quest, and almost no online product promotional materials go into the detail to confirm without doubt that they had the needed function
  • Jig to depress the dual clutch levers: also early in the online sleuthing I learned that it was without question that I would have to remove the clutch actuator assembly (PN 414702D011) -- whether to replace it, work on its subcomponents, or access a sensor hidden underneath it.
    • This component assembly is always in some state of pulling on at least one of the clutch levers, and one has to separately depress those levers further to relieve the tension on the assembly so that it can be easily removed and replaced.
      • I found a handful of jig sets online to for this, but all started at about $250, which was over my threshold for a single-task tool that I may never need again.
      • Could I rent locally, you may ask: I did something close to scouring Denver for it, and got a resounding "no."

Cut to the happy ending

• The full service manual for the dual-clutch transmission (DCT) was available on Sribd.
  • A close review of the service manual revealed a block diagram that showed clearly that the clutch position sensors (one for even, one for odd) ARE integrated into the "41480-2D000 ACTUATOR Clutch-Motor"
    • CONCLUSION: I only needed to replace that one part.
    • BONUS: price $160
• I located arguably the least expensive diagnostic tool (Mucar V07 bidirectional diagnostic tool) where the maker confirmed to me that it performed the "clutch touch point learning procedure"
  • PRICE $250
  • BONUS it is a robust, all-makes-and-models diagnostic tool that I'm likely to have many uses for -- as may my hobbyist friends
• Jig: I was able to dream up a simple, clutch-lever-depressing jig that comprises a) short length of EMT conduit; b) a bolt with 2 washers and 2 nuts; and c:) a short chunk of clear silicon tubing the act as a spacer
• Having attached the Mucar V07, I got a more detailed DTC code: P080564 - Clutch 1 Motor Hall Sensor Circuit. This clarified that Hall-effect sensors are used to detect clutch position, and that only the Clutch 1 sensor was the problem (clutch 2 sensor was apparently still working fine).

Grand finale

Armed with all of the above information, parts, and tools, I did the 41480-2D000 replacement. Then I used the Mucar V07 bidirectional diagnostic tool to run the DCT Learning Function (aka "clutch touch point learning procedure"). With all of that done, the problem was resolved. The dual-clutch transmission was shifting better than ever, and no further trouble codes occurred.

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