Ford Powershift: Blessing or Curse?
Car manufacturers constantly look for ways of improving performance characteristics of their cars and development of new types of transmissions plays an important role in this process. With the progress in transmission technologies, many carmakers started to use dual-clutch transmissions instead of standard solutions. One of these dual-clutch innovations (DCTs) is the Powershift transmission designed by Ford. In this article, we will consider the main features of this transmission, its design peculiarities, and typical repair issues.
What is Powershift
Powershift (DPS6/6DCT250) is a 6-speed dual-clutch transmission which
operates with the help of an automatic drive. This transmission was designed in
collaboration with Getrag.
In fact, this solution, based on a standard manual
gearbox, ensures that the gear shifting process is performed by actuators
(servo mechanisms, servo drives) under the TCM control.
In contrast to early Ford robotic transmissions with a single-plate clutch, Powershift is a pre-selective transmission with two clutches. In terms of design, the Powershift transmission is similar to the DSG solution (they differ in the number of gears). The availability of two clutches guarantees rapid gear shifting, almost no interruption in torque delivery, and high fuel efficiency.
Learn more about Ford Powershift
transmission
Powershift Design Peculiarities
The PowerShift design includes two drive gears which are actuated by 2 separate clutches. The remarkable design feature of this transmission is the availability of two input shafts (one shaft is located inside the other one). The first (hollow) shaft actuates even gears as well as reverse gear, while the second shaft (also known as “central”) is responsible for odd gears. Another feature of the PowerShift transmission is the lack of torque converter, planetary gear, and friction clutches. Thanks to this design peculiarity, the loss of engine power and torque turns out to be minimal.
PowerShift mechanisms are controlled by the TCM (transmission control
unit) located on the transmission case. The main function of the TCM unit is
the collection and processing of data from different sensors. After processing
the information, the TCM transmits signals to actuators and monitors their
operation. In addition, the control unit is responsible for the clutch
operation and gear shifting. It is performed with the help of DC motors with
integrated Hall sensors.
Principle of operation
The internals of Ford Powershift
If you want to understand how this transmission operates, you have to imagine two manual transmissions combined in one casing. The principle of operation of the PowerShift transmission is the following: when one gear is engaged, the following gear is pre-engaged (i.e. it is in mesh, but not engaged). As a result, the process of gear shifting is performed instantly. This result is achieved thanks to the fact the latest versions of PowerShift transmission use a “dry” dual-clutch (earlier versions use wet clutches and hydraulic actuation) in combination with the electromagnetic control.
Dual Clutch
The Powershift clutch is equipped with automatic wear adjustment feature and torque vibration dampers.
The Powershift clutch design includes the following:
- Clutch unit;
- Double release bearing;
- Electromechanical lever actuators (2 pcs.)
- DC motors (2 pcs.)
Powershift application
The one-millionth Powershift coming off
the line
The Powershift transmission is mainly installed on Ford (Focus, Mondeo, Fiesta, GT, Kuga etc.) and Volvo (S60, V60, V40, etc.) models. Thanks to its compact design, the Powershift transmission can be successfully installed not only on powerful sedans Ford Mondeo, but also on compact Ford Focus. This type of transmission can be installed on cars with longitudinal and transverse arrangement of the engine. Thus, this transmission solution can be installed on a wide range of Ford and Volvo models.
Pros and Cons of Powershift
The PowerShift solution is designed to combine the main advantages of
automatic and manual transmissions. On the one hand, this transmission ensures
the driving comfort thanks to smooth gear shifting as in automatic transmissions.
On the other hand, Powershift provides increased fuel efficiency because of
minimal losses of power and torque. Some experts believe that PowerShift is the
best solution for cars with high-powered diesel engines which provide high
torque.
Press releases always focus on advantages of the product. However, in
practice, owners of cars equipped with the Powershift transmission have to deal
with numerous issues related to the transmission. Transmission repair
specialists often hear complaints about electronic components of this
transmission system. Problems in operation of this transmission led to numerous
lawsuits against Ford all over the world. In many cases, transmission failures
require replacement of the whole transmission elements, resulting in high
repair costs. Frequently, drivers have to replace the problematic clutch (even
at relatively low mileage), if the car is used under severe conditions.
Learn more about a $10 million penalty
imposed on Ford because of Powershift transmission issues
This transmission can operate properly during its service life
(approximately 250 thousand kilometers) only under the condition of regular
maintenance service. It is also necessary to use original transmission fluids
recommended by the manufacturer and high-quality spare parts.
Typical repair issues
Transmission repair shops frequently have to deal with the following Powershift transmission issues:
- Jerks in the start-stop city traffic. This issue occurs in traffic jams (owners of Ford Focus frequently complain about this problem);
- Transmission fluid leaks. Leaks frequently occur in seals of the primary shaft. As a result, the transmission fluid gets on the clutch and leads to its slippage;
- Delays in gear shifting. This problem mainly occurs in the Powershift transmission with a dry clutch;
- Problems with the reverse gear in cold weather;
- Wear-out of seals. Due to this issue, the transmission starts operating irregularly;
- Failure of the TCM. This problem can be solved efficiently only by experienced technicians;
- Transmission overheating. This problem can occur even after several months of operation because of the transmission fluid shortage. Repair experts recommend checking the fluid level at each technical inspection.
Powershift transmission teardown
It is worth noting that, in most cases, the abovementioned issues occur due to violations of operating rules and ill-timed maintenance. Thus, it is absolutely necessary to follow all maintenance recommendations for the Powershift transmission. Do not forget to warm up the transmission in the winter time, it will improve lubrication of transmission parts and prolong the trouble-free service life of the transmission. Problems in the Powershift transmission can also occur, if the driver prefers aggressive driving. Technicians claim that this transmission does not “like” fast speeds with frequent gear shifting and it can rapidly get out of order.
Helpful tips on Powershift Maintenance
If you buy a car equipped with the Powershift transmission, it is
necessary to comply with the following operation rules:
- Engage the P gear only after you switch on the handbrake;
- If you activate the Sports mode, then the ± button must be disabled;
- When the car is in the parking mode, it should not be towed: it can damage the transmission, and the repair price may reach 50 % of the new transmission unit price. If the car breaks down on the highway, the car should be delivered to the nearest repair shop with the help of the tow truck equipped with the hydraulic manipulator;
- Regular transmission fluid change plays a crucial role in the Powershift service life. It is recommended to change the fluid every 50-60 thousand kilometers, and you won’t have serious transmission issues during 200 thousand kilometers. Untimely transmission fluid change may reduce the trouble-free service life of the transmission to 120-140 thousand kilometers, after that it may require some repair services. As a rule, Powershift should be filled with original fluids provided by such companies as Castrol, Liqui Moly, or SWAG. In addition to the transmission fluid, it is necessary to replace the oil filter.
Conclusions
The Powershift is a modern version of the robotic pre-selective transmissions. This solution ensures smooth gear shifting (unlike operation with jerks and delays typical for robotic transmissions with a single-plate clutch) without noticeable interruptions in torque delivery. In addition, cars with this transmission have high rates of acceleration dynamics. With each new generation of this transmission, the manufacturer tries to eliminate the most important drawbacks of the transmission, improve the software, and optimize algorithms of operation. In some cases, the automaker resorted towarranty extensions. However, all the efforts of Ford engineers didn’t result in permanent solutions for problems related to the Powershift performance. In comparison to similar dual-clutch transmissions (DSG designed by VW), the Powershift transmission is considered to be more reliable. However, this transmission is too far from being ideal and the statistics of breakdowns shows that this solution cannot be regarded as one of the transmission market leaders.
