Updated: Apr 25
This article relates to the Ford Powershift, DCT450 semi-automatic wet clutch gearbox that suffers various issues. This gearbox is found on Ford, Volvo, Dodge & Chrysler models including the, Mondeo, Galaxy, B-Max C-Max, S-Max, Kuga, Focus, Edge, C30, V50, C70, S80 and many more.
Ford Powershift | Wet Clutch or Dry Clutch?
Powershift dual clutch semi-automatic gearboxes are split into two main systems:
Wet Clutch (Includes 6DCT450)
Dry Clutch (Includes 6DCT250)
The 6DCT450 wet clutch system and the 6DCT250 dry clutch system are the two most common models on the UK market.
So what's the difference?
The 6DCT250 dry clutch system uses a conventional style dry clutch that you would see on a normal manual car. The clutch unit comprises of two friction discs each connected to one of the input shafts, which each control either the odd gear or even gears.
For more information on the 6DCT250 dry clutch gearbox click here.
The Powershift dual wet clutch transmission was designed and developed by Getrag transmissions, now known as Magna PT. This particular model of the dual clutch gearbox is used by four different manufacturers which included Ford, Volvo, Dodge and Chrysler.
In the Ford and Volvo applications of this transmission, the unit is commonly referred to as Powershift.
Compared to the 6DCT250 system, the wet clutch Powershift gearbox uses an automatic transmission style clutch setup. This consists of several friction and steel discs combined together in a stack. Each clutch, which are referred to as K1 & K2 in this setup up, are submerged in oil, which is the same fluid as used by the rest of the gearbox. It is for this reason that it is crucial that a full system strip down, clean and rebuild is required including mechatronic unit.
As the K1 & K2 clutches break down, as well as the torsion springs & plastic retainers, the loose debris circulates through the box. Some of this is caught by the magnet and two filters. However, as we have consistently seen, some of the material makes its way into the mechatronic unit.
This is why you must fully strip, clean and recondition the entire gearbox, otherwise the debris will destroy the mechatronic unit, requiring a replacement at around £1900 Inc VAT.
Common symptoms of a faulty Powershift gearbox
Harsh/Banging Into 1st & Reverse Gear.
Delayed Selection of 1st & Reverse Gear.
Clutch Slipping/ Vehicle Speed Not Increasing On Acceleration.
Jolting Motion On Gear Changes.
Transmission Malfunction Service Now Warning Light On Dashboard.
Please note you may experience some, but not all of the listed faults depending on the level of damage internally.
Components We Service/Repair On The Powershift Gearbox
When you are having issues with your Powershift semi-automatic gearbox, it is very important that the repairs are done properly, and no corners are cut. Time and time again we see customers who have had partial repairs or work done cheaply which has either caused further damage or their original repairs to be completely re-done. This is especially the case with clutch wear as mentioned above.
When the clutch pack is wearing down, the driver will experience rough gear changes and a banging, when selecting 1st or reverse, or sometimes in the higher gears.
If the driver continues to use their vehicle when the clutches and torsion dampening springs have worn down, it can result in damage to the clutch drum housing. The picture above shows were the torsion springs have worn or broken and dug into the housing of the clutch assembly. This component cannot be repaired or bought separately and requires a new complete clutch/drum unit, which increases the cost of repairs.
Pictured above is the broken torsion dampening spring that wears down and eventually breaks, resulting in clutch drum damage. This can be avoided by having your Powershift gearbox repaired at the early stages of wear, when the gear change issues are mild, and the engagement knock/bang is light. This is one of the most common issues we see with the Ford/Volo Powershift semi-automatic gearbox.
When repairing your Powershift gearbox, Eco Torque fully strips the gearbox, including the mechatronic unit. This is the only way to reliably repair these semi automatic transmissions, as the contamination enters the mechatronic causing operation issues.
If the common worn clutch unit is not replaced in good time, the material from the unit as well as other contaminants, enters the mechatronic unit and damages delicate components. This effects driving performance and causes issues like, getting stuck in gear, harsh gear changes or complete loss of drive.
We are one of only a few companies that fully strip down and recondition the entire gearbox and do not simply change the clutch, which will only cause further issues and require further expensive repairs.
Vehicle models affected
You can read about the action taken in America over the Ford Powershift gearbox here.
If you think your vehicle might be suffering from this fault and as with all gearbox issues, it is best to get it looked at straight away as it could save the customer substantial amounts on their repair bill.
Eco Torque offer an initial electronic diagnostic service with our main dealer equivalent machine. This shows us live data from the gearbox as well as a report for the customer to see the fault codes within the Powershift unit. This essential first step is £90 including VAT and takes around 1 hour to complete.
All of our Powershift repairs or recons come with a 24 Month 24'000 Mile Warranty.
We also offer 0% finance through Omni Capital Finance to spread the cost of the repair bill.
Eco Torque can also provide courtesy cars* as well as recovery* of your vehicle.
Contact Eco Torque Today:
Tel: 01462 835335 Email: firstname.lastname@example.org
Eco Torque Ltd
Unit 1A Portland Industrial Estate