Version 2 of the infamous powershift transmission - So what’s changed?
The Ford Powershift has gained itself a reputation and unfortunately not a good one. The second generation was released in the UK market around 2016, with various revisions to address some serious flaws in the system.
In this guide, we will explore these revisions and examine the ongoing issues it continues to face.
Clutch - Generation 1 vs Generation 2
Generation 1
This was the Achilles' heel of the first-generation Powershift, with 90% of failures stemming from the clutch itself or resulting from damage caused by its breakdown.
As some may know, the clutch featured an internal damping design, incorporating a large set of springs to reduce excess torsion and smooth out engine rev fluctuations. However, this design proved highly unreliable, as the springs often broke, leading to catastrophic damage to the clutch and, in some cases, the entire gearbox.
Generation 2
To address this issue, the second generation of the Powershift clutch eliminated the damping springs, returning to a more conventional design. A dual-mass flywheel (DMF) was introduced to replace the internal clutch springs, creating more of a standard configuration commonly found in other dual-clutch transmissions.
The second-generation clutch experiences significantly fewer failures compared to its predecessor. While it still undergoes regular wear and tear like all clutches, its primary cause of failure is typically the failure of the DMF.
Dual Mass Flywheel (DMF)
As mentioned, the dual mass flywheel was introduced to address the clutch failures on the previous generation.
Unfortunately, this has become one of the main failure points of the generation 2 system. The most common issues we see here are:
DMF Wear & Tear
The lifespan of dual-mass flywheels can vary significantly based on how the vehicle is used.
They are particularly sensitive to heavy loads or towing, which can shorten their average lifespan by as much as 75%. Since many of the Ford models equipped with these flywheels are family cars often used for towing caravans, the failure rate becomes quite evident, even in vehicles that are regularly serviced and well-maintained.
DMF Contamination
We have seen many flywheel failures due to oil and / or coolant leaking into the bellhousing and damaging the DMF.
This fault results in harsh banging when changing gears or complete failure, damaging the gearbox beyond repair.
This component can be changed independently and does not usually require a strip down of the transmission.
Synchromesh Failure
Another common issue we encounter is synchromesh failure in 2nd, 3rd, and 4th gears, often accompanied by an audible grinding noise. In a dual-clutch transmission, this can occur during both acceleration and braking, as the gearbox pre-selects the next gear in anticipation of the shift.
Repairing this fault requires a complete strip down of the transmission to replace the damaged components. Additionally, it is essential to carry out a thorough cleaning of all parts using a rigorous process to eliminate any debris or contaminants. This step is crucial to prevent damage to sensitive components such as the mechatronic unit.
Mechatronic Unit
The mechatronic remains a significant weak point, with minimal changes from the first-generation models. Unfortunately, it is a common component that requires replacement when addressing faults in this transmission.
With approximately 8 out of 10 repairs involving the replacement of this part, the Powershift continues to be a costly transmission to repair and return to working order.
Need Workshop Repairs?
Contact our workshop today on 01462 835335 or email us on info@eco-torque.co.uk, if you need help with your gearbox.
Get In Touch
Have you experienced any problems with your car? We’d love to hear from you! Share your feedback by leaving a comment below. We look forward to learning about your thoughts and experiences.
For specific enquiries, please reach out to us directly using the contact details provided below.
For more information 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
1 comment
Unfortunately, I recently purchased a 2012 Ford Focus with under 39,000. mi. on it. I had to deplete my savings for this purchase & now, less than 4 months later I am without a vehicle because the clutch assembly has failed & will cost approx. $4000. to repair. I am 77yrs. old, living on SSI & the owner of a useless vehicle. Thinking that a car with such low mileage was a good buy I am now without a car or savings.
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Eco Torque replied:
Hi Kathleen,
Thank you for taking the time to share your story. We are deeply sorry to hear about the challenges you’re facing with your 2012 Ford Focus. It’s disheartening to learn that what seemed like a reliable purchase has led to such unexpected and costly issues, especially given your situation. The struggles with the Powershift transmission are unfortunately a common concern among owners of certain Ford models from that era, as detailed in our blog. While it may not solve the immediate problem, you may want to check if your vehicle’s VIN falls under any service bulletins or extended warranties Ford may have offered for this specific issue. Occasionally, manufacturers offer goodwill repairs for known defects, even outside warranty periods, particularly for owners experiencing severe hardship. Additionally, reaching out to local consumer protection agencies or automotive advocacy groups could help explore options for financial assistance or legal recourse. Some non-profits also provide aid to seniors dealing with unexpected transportation challenges. We truly empathise with your situation and hope you’re able to find a resolution soon. If there’s any other information or resources we can help you with, please don’t hesitate to ask.