Intro
The Ford Powershift gearbox is fitted to some of Ford’s most popular models, including the Fiesta, Focus, Mondeo, and Kuga. While these dual-clutch gearboxes offer smooth gear changes and improved fuel economy, they are also known for reliability problems.
In this guide, we’ll cover the most common Ford Powershift gearbox problems, the symptoms to watch for, and the repair options available.
What is the Ford Powershift gearbox?
The Powershift is a dual-clutch automatic transmission (DCT) designed by Getrag for Ford. Unlike a conventional torque converter automatic, the Powershift uses two clutches to pre-select gears, giving faster shifts and better efficiency.
Two main versions exist:
- 6DCT250 (Dry Clutch) – used in smaller engines like the Fiesta and Focus.
- 6DCT450 (Wet Clutch) – used in larger, higher-torque vehicles such as the Mondeo and Kuga.
Common Ford Powershift gearbox problems
What are the symptoms of a failing Powershift gearbox?
- Jerky shifts or banging into gear → Often caused by mechatronic valve body or hydraulic faults.
- Slipping clutch → Premature wear of clutch packs on both wet and dry systems.
- Delayed gear selection → Hesitation when moving off, linked to solenoid or hydraulic pressure issues.
- Vehicle stalling at junctions → TCU (Transmission Control Unit) logic or clutch control failures.
- Warning messages → “Transmission Malfunction – Service Now” appearing on the dashboard.
Known issues by gearbox type
6DCT250 (Dry Clutch)
- Premature clutch wear.
- Leaking input seals.
- Jerky engagement in 1st and Reverse.
- TCM failure
6DCT450 (Wet Clutch)
- Clutch pack internal failure (Spring system collapse).
- Mechatronic hydraulic pressure loss.
- Debris blocks oil pathways.
What causes Ford Powershift failures?
- Clutch pack design flaws leading to premature wear.
- Hydraulic leaks inside the mechatronic valve body.
- Heat build-up in heavy traffic or stop/start conditions.
- Software calibration issues in the TCU.
Can you still drive with a faulty Powershift gearbox?
Short answer: yes, but it’s risky.
Driving with symptoms such as slipping, banging into gear, or dashboard warnings can cause further damage to the clutch drum housing, valve body, or mechatronic circuits.
👉 Early diagnosis and repair almost always mean lower repair costs.
Repair & rebuild options
At Eco Torque, we specialise in Powershift gearbox repairs and parts supply. Options include:
- Clutch replacement kits for 6DCT250 and 6DCT450.
- Mechatronic repairs or replacements (including TCU data cloning).
- Full gearbox rebuilds in our Arlesey workshop.
🧰 Browse our Ford Powershift parts collection↗
Ford models fitted with the Powershift gearbox
- Ford Fiesta
- Ford Focus
- Ford Mondeo
- Ford Kuga
- Ford Galaxy
- Ford C-Max / S-Max
Frequently Asked Questions (FAQ)
Q: How much does it cost to repair a Ford Powershift gearbox?
Repairs typically range from £1,000–£2,500, depending on whether you need a clutch kit, mechatronic repair, or a full rebuild.
Q: Which Powershift gearbox has more problems — wet or dry?
Both versions can fail, but the dry clutch (6DCT250) is particularly known for early clutch wear.
Q: How do I know if my Powershift needs repair?
Look for slipping clutches, banging into gear, hesitation, or dashboard warnings such as “Transmission Malfunction – Service Now”.
Conclusion
The Ford Powershift is an advanced gearbox, but issues with clutch wear, mechatronic units, and TCU calibration are common across both 6DCT250 and 6DCT450 systems.
If you notice early symptoms — from jerky shifts to warning lights — don’t wait for a full failure.
👉 Trust Eco Torque, specialists in Ford Powershift gearbox repairs and rebuilds:
- 📖 Read more on our Eco Torque Blog↗
- 🧰 Browse our Ford Powershift parts collection↗
- 🚗 Book a repair at our Arlesey workshop↗
We Want To Hear From You!
Leave a comment at the bottom of the page and let us know if you have experienced this! If there are vehicles, gearboxes or issues you want us to discuss, let us know!
Contact Eco Torque today
Tel: 01462 835335
Email: info@eco-torque.co.uk
Eco Torque Ltd, Unit 1A Portland Industrial Estate, Hitchin Road, Arlesey, United Kingdom, SG15 6SG
8 comments
Hi I have a 2010 ford Mondeo power shift playing me up, cars only done 60k ,and I am getting a few different fault codes ? Sometimes it will drive and sometimes it won’t ? I do have an image of fault code readings off my autel scanner , I do realise it’s better to have live diagnosis. Was just wondering what the prices are roughly for a full refurb? Thanks for any assistance regards Joe.
———
Eco Torque replied:
Hi
Thank you for your comment, i have emailed you privately with some questions regarding your car to help better diagnose the problem.
Kind Regards
Steven Lamont
Workshop Manager
Eco Torque
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Hello
I have a Ford Mondeo 2011 year of production, 2.0 dci with auromatic transmission Power shift. The gearbox is broken because 1st gear and 3rd gear are working. It does not change to other gears.
Please give your opinion on the error according to the symptoms mentioned.
A nice greeting
Sasa
Hello! I’m about to buy a 2019 Ford Focus 1.5 ecoboost 150 hp 7 speed automatic transmision! Does that gearbox have the same problems? Should I avoid Ford’s automatic transmision? Thank you!