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
Hello
I’m so happy to have found this webpage.
My car today while cruising trough Poland started slipping the gears, basically didn’t brake down but still became un-drivable.
I read that it needs the gearbox to be removed and the clutch to be replaced.
How much would this work cost in the UK?
I’m just asking so that I have an idea.
Thanks a lot in advance!
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Eco Torque replied:
Hi David
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
Hi,
Excellent article and summary, even for the less ‘technical minded.’ Thank you.
I have a 2014 Focus with Powershift I believe which had done 71K (low average mileage).
Are you aware of Ford UK issuing public advisories or agreeing to diagnosis + TCM replacement + clutch replacement? The Australian courts fined Ford $10million for misleading customers over there on the issue.
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Eco Torque replied:
Hi Mike,
Thanks for your comment, and we’re glad you found the article helpful! We’re aware of the class action in Australia, and while Ford UK hasn’t issued the same kind of public advisory or blanket support for repairs, there have been isolated cases where they’ve assisted—typically within or just outside warranty periods and often on a case-by-case basis. We’d always recommend speaking with your local Ford dealer if you’re experiencing issues, but do keep in mind that official support can vary depending on the service history and specifics of the fault. If you’d like to get your vehicle checked over, we offer a full diagnostic service and can advise on any underlying problems with the Powershift system. ________________________________
Hi got a 2010 galaxy 2.0 diesel . Powershift problem it’s slipping and getting hot. And very jerky 😔 can’t drive it. How much for this box to be repaired or a recon box
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Eco Torque replied:
Good Afternoon Michael
What reg is the car, so i can take a look at what type of gearbox it is?
Feel free to email me directly @ “info@eco-torque.co.uk” or give us a call on 01462 835335
Kind Regards
Steven Lamont Workshop Manager
I’m looking at a 2015 used Galaxy 180bhp Tdci Powershift. I am unsure if this has DCT450 or 2nd gen DCT451 gearbox. How can I find out. Reg SR65FTA
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Eco Torque replied:
Hi Peter
Based on that reg it is a Gen 2 powershift. Anymore questions feel free to give us a call.
Kind Regards
Steven Lamont Workshop Manager
We have a 2016 Ford C-Max that came up with a sudden Transmission power failure code 12 hours after purchase. Car now doesn’t drive other than reverse. It has been diagnosed as needs refurbished gearbox. Cost is more than the car is worth. Could you give a rough estimate of how much you would charge.
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Eco Torque replied:
Hi Linda
Of course, do you have the reg please?
Feel free to email me direct @ “info@eco-torque.co.uk” or give us a call on 01462835335
Kind Regards
Steven Lamont Workshop Manager