Preparation work
Overview
| This procedure describes the process required to drain and refill the Dual Clutch transmission (DCT) clutch oil. It is important to fill the DCT clutch chamber with the correct amount of oil. If the oil level is set incorrectly faults can occur with the DCT and related systems. The drain and refill procedure is the same for all models apart from the final fill level which is specific to each model.
The clutch oil drain and refill procedure must be done twice if the following occurs:
| • | The airbrake system is changed or drained.
| | • | There is any doubt that the clutch fluid has been drained prior to the drain refill procedure.
| | • | Any of the transmission mechatronics have been changed
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Vehicle preparation.
| 1. | If an airbrake wing is installed, put in the retracted position.
| | | 2. | Run the vehicle to raise the clutch oil temperature to between 30°C and 50°C.
| | | 3. | Make sure the Air Conditioning (A/C) is set to off.
| | | 4. | Put the vehicle on a ramp.
| | | 5. | Raise the vehicle so that the wheels are not in contact with the ground.
| | | | | Care Point: | Leave the drivers door open during the next step.
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| | | 6. | Start the engine.
| | | 7. | Perform the below sequence in the vehicle:
Perform an airbrake bleed procedure.
Drive (D) for 6 seconds.
Neutral (N) for 6 seconds.
Reverse ®) for 6 seconds.
Select (N) and turn the engine off.
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Clutch oil drain procedure
| | | Care Point: | Before you remove the oil fill and drain plugs make sure that the oil can drain into a container with a capacity of at least 8 litres.
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| | | 1. | Remove the oil fill plug (1).
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| 2. | Remove the oil drain plug (2).
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| 3. | Remove the oil drain plug (3).
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| | | Care Point: | If installed, it may be necessary to remove the Z bar to access the oil filter cover bolts.
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| | | 4. | Remove the bolts (4) and filter cover (5).
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| 5. | Pull the filter (6) away from the housing (7) to remove.
| | | 6. | Allow the oil to drain from the filter area and drain plugs at the same time.
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| 7. | When the oil has drained completely install the drain plug (2) and (3) with new sealing washers. Tighten to 40 Nm.
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| 8. | Renew and install the oil filter. Make sure the filter cover O-Ring (8) is not damaged. Replace the O-ring if necessary.
| | | 9. | Install the filter cover bolts (4). Tighten to 10 Nm.
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| Care Point: | It is not possible to fill the clutch oil in one operation. Make sure you follow the procedure.
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Clutch oil fill procedure
| 1. | Fill 5.5l of FFL-4 clutch fluid through the fill plug (1).
| | | 2. | Install the fill plug (1) and partially tighten as you will need to remove it again in the following step.
| | | 3. | Raise the vehicle so that the wheels are not in contact with the ground.
| | | | | Care Point: | Leave the drivers door open during the next step.
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| | | 4. | Start the engine.
| | | 5. | Put the transmission into the following modes:
Drive (D) for 6 seconds.
Neutral (N) for 6 seconds.
Reverse ®) for 6 seconds.
Select (N) and turn the engine off.
| | | 6. | Remove the fill plug (1) and add the amount of FFL-4 clutch fluid stated in the following table.
Clutch oil capacity by vehicle model.
Vehicle Model
| Second Stage Fill Volume
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MP4-12C
| 1.3L
| 650S
| 1.3L
| 675LT
| 1.1L
| P1
| 2.5L
| 540C
| 0.7L
| 570S/GT
| 0.7L
| 600LT
| 0.7L
| 620R
| 0.7L
| 720S
| 1.5L
| 765LT
| 1.5L
| SENNA
| 1.8L
| ELVA
| 1.8L
| GT
| 0.7L
| SPEEDTAIL
| 2.5L
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| | | 7. | Install the fill plug (1) and tighten to 40 Nm.
| | | 8. | Install the components in reverse order.
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