2011 Ford Focus Sport, Transmission Shudders :(

[chappy60]

had our clutch and drive shafts relaced at 15000kl symptoms were shuddering weird
noises and failing to go back to 1st when stopped and stalling on take off a couple of times

[damo76]

Focus went back into ford today and they test drove it and did other tests to find gearbox neads to be taken out again for further inspection, car is 61000km this is second time.

[alokin123]

Although from an America site, its still outlines Ford's logic:

http://lemonlawassociates.com/extended-warranty.html

Here's Why Ford Extended The Warranty On The Fiesta And Focus


Ford recently began notifying the owners of 2012 and 2013 Ford Focus and Fiesta models that they will receive an extended warranty. This is due to the fact that the transmission clutch has a shuddering problem. The previous warranty was for 5 years or 60,000 miles, while the extended warranty now covers 7 years or 100,000 miles.

The warranty covers the PowerShift 6-speed transmission, specifically the transmission's software calibration, clutch, and input shaft seals. Ford is currently producing a revised clutch, new shaft seals, and a software update. They think the shudder issues are caused by leaking transmission seals.

For Focus and Fiesta owners who have already put more than 100,000 miles on their vehicles, Ford extended the warranty until January 31, 2015. As for those who've paid out of their own pocket for repairs to address the shudder issue, they may be able to get a refund through the Ford Customer Satisfaction program. This information should've been included in the notifications sent out by Ford.

Ford has enabled its dealers to provide free service to those whose cars are affected by the transmission shudder.

This may seem like an odd move to many people who had noticed issues with their cars before. Chances are, if you complained to the dealer or to the company itself, you were told that everything was normal and there was nothing to be fixed. Why, then, did Ford change their tune and begin offering extended warranties and free service? And what does it mean for you, as an owner affected by the shudder issue?

Ford introduced this particular transmission in 2011, in both the Ford Focus and the Ford Fiesta. The transmission is known as a Dual Power Shift transmission (henceforth the DPS6). Initially, the transmission was described as automatic, and the company boasted that it made cars fun to drive and provided a smooth ride.

Unfortunately, the DPS6 doesn't perform like an automatic transmission, and drivers quickly noticed that the vehicle would shudder or jerk when shifting. The issue was particularly pronounced when accelerating from a stop. When owners went to the dealerships, many performed repairs under the warranty, but these repairs didn't resolve the issue.

To better understand the issue, it's important to know that the DPS6 is in fact the combination of two manual transmissions joined together. Because of this, vehicles with the DPS6 have two clutches instead of one. The transmission is controlled by a computer, which shifts the gears as needed. So, the Ford Fiesta and Focus models are not actually automatic transmissions, they're manual transmissions controlled by a computer.

When the early repair attempts were unsuccessful, Ford adopted a new approach. They notified their dealerships that the complaints they were receiving about the transmissions were in fact unnecessary. They claimed the vehicles were behaving normally, and the jerks and shudders were part of how the transmission was supposed to work. Of course, these issues were never considered normal when they were selling the car, just when customers had issues later.

In fact, many dealerships actually showed the documents they received from Ford to their customers, hoping to show that the vehicles were working normally. Plenty of dealers would not even include transmission issues on their repair orders, because they classified them as normal.

It is clear that Ford knew that the DPS6 had significant issues, but they did not change their marketing descriptions or the warranty for some time. In fact, they knowingly sold these vehicles while hiding the facts of the transmission issues.

This becomes apparent when you look at the TSBs Ford has issued over time. TSBs are advisories issued by car makers when they see new, common problems arise. They are circulated among dealerships and mechanics to enable them to solve common issues quickly.

In September of 2013, Ford released TSB 13-9-4, which described a clutch shudder and fluid leak in the DPS6. In March 2014, they released a new TSB that proposed a pinpoint test to determine whether the transmission had an issue. It is likely they created this test in order to maintain their position that most of these transmissions were operating normally.

And in July 2014, Ford released one further TSB regarding the DPS6. This one tweaked the description of the shudder issue.

It seems clear that Ford is attempting to paint the transmission issues as not being the result of a design defect. This is because the new vehicle warranty would cover design defects, and potentially cost Ford significantly more.

The transmission issues in the Ford Focus and Fiesta may very well be caused by design defects in the DPS6. Contact Lemon Law Associates today to learn about your options.

[KosCo]

For those who are interested in the new LZ Ford Focus changes --

Due around October 2015
1.5 litre ecoBoost engine
NO powershift - back to a slushbox transmission (what does that tell you)

Look here for further details --

http://www.carsguide.com.au/car-news...s-prices-34088

http://www.carsguide.com.au/car-news...es-price-34029

[In Focus]

I don't think the powershift is available on the 1.5 Ecoboost. Of course, that might have been a big reason why the 1.5 Ecoboost was chosen as the new powerplant of (sole) choice...

[damo76]

Well the focus went in to ford for a second time last week to get a new clutch.
Drives better now but there is still a very feint shudder on takeoff.
Oh well warranty runs out in two months time to get rid of it.

[mik]

Originally Posted by damo76

Well the focus went in to ford for a second time last week to get a new clutch.
Drives better now but there is still a very feint shudder on takeoff.
Oh well warranty runs out in two months time to get rid of it.

Thats bad luck Damo76 , one has to wonder how a big world wide company like ford that has been in business for over a hundred years could get this so wrong.

[marg99]

I am not surprised, look at the ball joints on the Territory & the diffs in the falcon.

[awbeattie381]

Wow glad I found this thread! We have a 2014 Trend DSG and its becoming a real bugger to drive which is a shame because I really like the car and this just makes me angry having such an annoying issue with such a new car.

We have been to the dealer once with the shuddering issues, earlier this year with about 10,000km on the clock. Dealer couldnt find any faults and did some 'software upgrade'. Didnt make a scrap of difference. Car is getting worse.

Sometimes its worse in really cold weather, sometimes its worse in really warm weather. Seems to be no consistency. Another issue is sometimes the car wont find reverse and you have to move the gearstick through the gears again and reselect reverse. Sometimes the car just feels like it skips a gear/or falls out of gear and jolts back in again. Makes for a really uncomfortable ride!

Looks like another trip to the dealer considering the issues we are having are REAL!

We also have issues with the rear parking sensors intermittently but thats another story.

Other than that we are really happy with the 25,000km so far...love the look, love the feel (other than gears), love the power at top end and love the handling.

Andrew

[SpoolMan]

Hi and welcome to the Form..

Keep sticking it to the dealer if you have no luck ring Ford customer service, your right there a great car let down my some very poor engineering with the trans..

[awbeattie381]

Thanks for the welcome and yes we will be going back to the dealer after reading all of this...ill keep you posted!

[damo76]

There is some one that lives near us with the same 2012 focus sports and she posted on the local facebook page how her focus has been in to ford for 4 new clutches and the problem is still there.
I can expect to see a lot of focus's at the tip in a few years.

[martinijosh]

Our '12 fiesta is going back for clutches and sensor again.

[buggerlugs]

Slightly off topic, but the daughters 2011 Focus Sport Turbo Diesel just had the air con re gassed and "Engine Malfunction Service" light has come on the dash about a week later. Are Ford the only guys to check this sort of thing ?

[SpoolMan]

I would start a new thread on the topic.

[marko]

Originally Posted by buggerlugs

Slightly off topic, but the daughters 2011 Focus Sport Turbo Diesel just had the air con re gassed and "Engine Malfunction Service" light has come on the dash about a week later. Are Ford the only guys to check this sort of thing ?

Since it's out of warranty somewhere Auto Masters of the like who have proper diagnostic machines will do

Sent while boosting ....

[KosCo]

My Focus is a 2012 Titanium which has just had its 3rd birthday. Had the gearbox shudder problems and had it repaired not long after I got the vehicle. I have received the letter from Ford about the warranty on the gearbox being extended to 5 years.

The gearbox has been good since the original repair, however have been noticing the shudder creeping back into the gearbox. It is mostly noticeable in low gears either going from 1st to 2nd or 2nd to 3rd - more so if the vehicle has to labour a bit such as going uphill.

It is currently not as bad as the original shudder which was quite bad such that it would make you grit your teeth - currently the situation is noticeable and annoying. Also have to mention that of course it doesn't happen all the time but generally experience it on every drive.

The car is due for a service soon and am going to mention the problem - just so that it goes down on the record. Does anyone have experience or knowledge as to how bad the shudder has to be before it is re-considered as being needed to be repaired? Is Ford still trying to ignore the problem? Is there still a backlog on parts?

Any help much appreciated.

[kevino]

Our fiesta 2012 with power shift. One clutch replaced at 17500 another at 35000 now at 41000 no shudder but the changes under heavier throttle can confuse it.
Expect it to be shuddering and playing up by 52000kms. Have no confidence whatsoever with these powershift gearboxes.
Our other car a 2008 diesel with six speed manual clutch never touched gearbox fine and it has done 224000kms.

[kevino]

That's a 2008 focus diesel.

[Top_Ghia]

Originally Posted by KosCo

My Focus is a 2012 Titanium which has just had its 3rd birthday. Had the gearbox shudder problems and had it repaired not long after I got the vehicle. I have received the letter from Ford about the warranty on the gearbox being extended to 5 years.

The gearbox has been good since the original repair, however have been noticing the shudder creeping back into the gearbox. It is mostly noticeable in low gears either going from 1st to 2nd or 2nd to 3rd - more so if the vehicle has to labour a bit such as going uphill.

It is currently not as bad as the original shudder which was quite bad such that it would make you grit your teeth - currently the situation is noticeable and annoying. Also have to mention that of course it doesn't happen all the time but generally experience it on every drive.

The car is due for a service soon and am going to mention the problem - just so that it goes down on the record. Does anyone have experience or knowledge as to how bad the shudder has to be before it is re-considered as being needed to be repaired? Is Ford still trying to ignore the problem? Is there still a backlog on parts?

Any help much appreciated.

Ford dealers use a computer to measure the shudder under certain driving conditions. Shudder is measured in rpm on the input shaft speeds. Shudder in excess of 250 rpm is enough to warrant repairs which may include a new clutch. This data is recorded and supplied to ford for verification for warranty repairs.
When was the last time the software was updated? Quite often the latest software calibration is enough to rectify the shudder.
So what does 250rpm of shudder feel like? Well it's certainly noticeable but far from severe. Severe shudder would be 500+ which sounds like where you were before.

[KosCo]

My thanks for the information supplied. At least I won't go in entirely blind. I think the last software update was done at the time of the original problems and the gearbox was then repaired.
Will see what they say when I take in in next week.

[Top_Ghia]

Originally Posted by KosCo

My thanks for the information supplied. At least I won't go in entirely blind. I think the last software update was done at the time of the original problems and the gearbox was then repaired.
Will see what they say when I take in in next week.

How long ago was that work done?
If they give you the brush off and say it's ok, ask them what the shudder measurement was.

[SpoolMan]

Ford are conditioning the owners to except some level of shudder, I have been through the whole process with Ford customer service.
Ford having tolerances for shudder is a cop out, no auto trans should shudder.
Its no surprise this DSG setup is gone from the new model.

[GTLEGEND]

Originally Posted by kevino

That's a 2008 focus diesel.

The diesel focus uses a wet clutch version of the Powershift trans, fitted to diesel focus and all mondeo. Note this transmision was introduced to Focus in 2009, and Mondeo in 2010, prior to this the Focus was fitted with a 4 speed torque convertor auto, and the Mondeo with a 6 speed auto,so I am not sure that your 2008 Focus is a Powershift?

The two Powershift boxes are totally different and sould not be mixed up with each other or with the previous auto transmissions..

[GTLEGEND]

Originally Posted by SpoolMan

Ford are conditioning the owners to except some level of shudder, I have been through the whole process with Ford customer service.
Ford having tolerances for shudder is a cop out, no auto trans should shudder.
Its no surprise this DSG setup is gone from the new model.

The shudder tolerence by Ford is at a level where it is not noticable unless you actually see it on a graph. Thats why action can be taken if the shudder is above that spec. Remember the trans is really a manual trans with an electronic clutch so the "auto" part is that the driver does not have to shift. You really cannot compare it to a tradional torque convertor auto. Just like a normal manual vehicle, some shudder is evident under certain conditions and this is normal and acceptable. I think that most people just dont like the characteristics of this style trans which is also fitted to many other makes/models and that is fair enough...

But when the trans is operating (nice positive acceleration) well, the transmission drives really well and quick between shifts. It just gets confused with hesitant drivers, drivers that drive with two feet or hold the vehicle stationary with the accelerator instead of the brake (burns the clutch just like a normal manual).

Note the DPSG is still available in other countries (US and Europe) on the new model (most of them are used to manual trans characteristics) but the volume in australia does not justify having so many engine/trans variations.

Pity there were other factors like oil leaks that spoilt the operation of the clutch/powershift...

[AllCoupedUp]

I had the exact same issues as the OP in my 2012 Sport.

From day one, it shuddered bad and actually stalled on me on one occasion. After 6 visits to ford over the first 3 months of ownership I gave up. I got the ford line of, "it's within tolerance". And yet their loan car didn't do it!! Anyway, it got reflashed every visit and then sent on my way.

2 years into ownership and I got the letter extending the warranty. Took it in again, went through all the same rigmoral and ended up same result - told its fine.

Zoom forward to August, due for 60k service. Tell service guy my thoughts and he tells me that he'll check it out and run the tests. Get a call that arvo - g'box is cactus. One of the worst he's seen. Said to me that I should have notified them earlier... I told him to read my file - there was silence from his end once he read it.

End result - g'box overhaul and new flash. Felt muuuuch better, but damage done. Traded it 2 weeks later and bought Mondeo from another dealer.

To the OP - there is a designated test that ford now do for the boxes - demand that it be tested. Good luck & do what I did, sell it and by the new Mondeo (wet clutch) - awesome car.

[SpoolMan]

Originally Posted by GTLEGEND

I think that most people just dont like the characteristics of this style trans which is also fitted to many other makes/models and that is fair enough...

.

Who wants to drive a car with shudder, Ford say its the characteristics of there DSG which makes me laugh when you jump into other brands with DSG and you don't feel any difference and no shudder.
They should have told us before we purchased for $29k it was going to shudder.
Who would buy a Ford DSG if they were informed on the purchase we expect your DSG to shudder its the characteristics of these Ford models.

[GTLEGEND]

Originally Posted by SpoolMan

Who wants to drive a car with shudder, Ford say its the characteristics of there DSG which makes me laugh when you jump into other brands with DSG and you don't feel any difference and no shudder.
They should have told us before we purchased for $29k it was going to shudder.
Who would buy a Ford DSG if they were informed on the purchase we expect your DSG to shudder its the characteristics of these Ford models.

Totally agree with you mate... My point was that if you are feeling a shudder then there most probably an issue with your box.. the shudder is not a characteristic I was talking about, moreso the hesitation under some conditions or driving habbit..

[Binny]

Originally Posted by GTLEGEND

The diesel focus uses a wet clutch version of the Powershift trans, fitted to diesel focus and all mondeo. Note this transmision was introduced to Focus in 2009, and Mondeo in 2010, prior to this the Focus was fitted with a 4 speed torque convertor auto, and the Mondeo with a 6 speed auto,so I am not sure that your 2008 Focus is a Powershift?

The two Powershift boxes are totally different and sould not be mixed up with each other or with the previous auto transmissions..

He said it's a manual. The 2007-2008 TDCi was manual only, there wasn't an auto option on the TDCi at all until the powershift came out in the LV.

[GTLEGEND]

Originally Posted by Binny

He said it's a manual. The 2007-2008 TDCi was manual only, there wasn't an auto option on the TDCi at all until the powershift came out in the LV.

Oops my bad, read that important part wrong!!