Hyundai I40 Gearbox & Transmission Problems

This model Hyundai i40 had two different automatic transmissions depending on which engine was fitted. If you have the petrol engine, the transmission will be a conventional torque converter six-speed automatic. However, if your car has the turbo-diesel engine, the transmission will be a seven-speed dual-clutch unit. At which point things change.

These dual-clutch units (and not just Hyundai’s) have shown themselves to be a bit under-engineered in some respects. And when they start to develop wear in the clutch packs, they can definitely start to behave poorly including rough shifting, shuddering when moving off and other problems.

But either way, you are going to need the services of a transmission specialist to determine what’s wrong. Even if you have the conventional automatic version, you might still find it has serious internal wear or failures, but only a detailed diagnosis will tell you the whole story.

On the other hand, you might be lucky and simply have a transmission with low fluid level that will be restored to health by a top up of that fluid. You’ll still need to find from where it’s escaping, however, as this is a sealed system and should not lose fluid over time.

As I am sure you have been told clutches are considered wear and tear items and as such are not covered by the warranty. If it's found the cause is something other than a worn clutch rectification would possibly be covered by the warranty, but if it's shown to be a worn clutch you will be up for the cost of repairs, which will include the cost of tearing it down. I don't see there's any escaping that cost.