2011 Ford Focus Sport, Transmission Shudders :(

[LeadFoot81]

Took the Mrs' car to the dealership on Monday, and got it back Thursday. Very happy with the turnaround time.

On visual inspection they found that there was transmission fluid in the clutch housing. The trans was removed and clutch assembly, input shaft seal, and trans fluid were replaced.

I've only driven the car briefly, but it drove 'like new' Shifts are quick and tight, and the car feels perkier down low (no slipping clutch). The biggest change was reversing which has gone from a 'shuddering and about to stall' feeling, to behaving (almost) like a regular slush box.

I'll post updates as the KMs are racked up. Fingers crossed it all stays good!

[Golfer]

I have been watching this thread with interest even though I have a diesel. I hope everyone gets things sorted because the transmission on our car is fantastic.

[LeadFoot81]

Yeah when its in good working order, the transmission really makes the car: quick smooth shifts, good power delivery, and very economical.

[scottyg]

Add another one to the list with the shuddering transmission. We DID have a nice late 2011 Titanium with the trick 6 speed box. After 3 software upgrades and a new clutch pack, the child bride yelled "ENOUGH". The thing was a POS to drive even after all the warranty work. Result is the Titanium is gone and there is now a Bimmer in the shed. Nice one Ford. Another long term customer is lost. I will just have to drive the Landau and Escort now and remember the good old days..........

[marg99]

any one know how much a clutch pack is for these new transmissions as I assume they wear out even when working well after 100K

[THAXR5]

Hey guys

Been reading all the post above and have a similar issue in the mrs sports lwmk11, with an added bit does all the shuddering etc but after last service had it back for a week and the mrs was driving to work when she said it felt like it lost power and as my mrs does keep driving to work engine light on :-( got to work and it would not go into reverse it would just rev she tried starting and stopping 4-5 times before it finally went into reverse. Took it to the dealer and they said it was a software update fair enough I said ( before reading this) but was driving it today and it drives like a bucket of bolts. Right at the end of the drive felt sluggish no power went to reverse up the driveway and it is not a steep driveway it only just made it up there full throttle.
Is this the same problem people are having what should I ask for them to look at?

Cheers Wayne

P.s 2012 model 18k on the clock

[KosCo]

See how the software upgrades goes but sounds as if the problem is more serious. My experience was only with shuddering and the software upgrade helped but still had the shudder. They eventually replaced parts in the gearbox and that fixed the problem - back to running like new and hopefully stays that way.

Your problems seem much worse than the shudder problem and suggest that gearbox needs pulling apart.

[kelvinyhm]

An update of my car after the transmission update 2wks ago.

Apparently the shudder and noise has gone for the stop and go. Different kind of shudder now, on highway..speed around 90kmh, once slowed down to about 60kmh and accelerate hard again, a slight shudder is there during the hard acceleration. No noise. (tested 1 wk ago).

Reverse gear no change from before update. It has lil low noise kluk kluk kluk....

Will try again this weekend.

[Yellow_Festiva]

Originally Posted by marg99

any one know how much a clutch pack is for these new transmissions as I assume they wear out even when working well after 100K

Between 6 and 7k.

[kevino]

Or extend the warranty another 3 years -$1700.
Only works I guess if you have an interested and helpful Ford service mgr.

[Imolator]

Originally Posted by Yellow_Festiva

Between 6 and 7k.

The complete transmission (including clutch pack) sells for $3995US dollars in the states on Ford Parts.

Over on FocusFanatics it was reportedly $1200US for the clutch pack fitted.

For the price above I would expect a new transmission. Then again we do get royally reamed on parts pricing here.

[Yellow_Festiva]

Originally Posted by Imolator

The complete transmission (including clutch pack) sells for $3995US dollars in the states on Ford Parts.

Over on FocusFanatics it was reportedly $1200US for the clutch pack fitted.

For the price above I would expect a new transmission. Then again we do get royally reamed on parts pricing here.

That is what I was told by the service Dept manager at a dealership. Ford footed the bill but had I been a regular customer apparently that is what my bill would be.

Pricy... ay. Now, I would love to know if anyone is in the Ford parts Dept on here to see what they retail for. Whole tranny, clutch packs, and the comparable cost for manual tranny and clutch.

First, to see what the markup is, second to see what the labour is and thirdly to see if the $1500-2000 they charge for the auto lulls people into a false sense of thinking that there isn't much difference in cost between them.

I bloody loved our diesel focus. Pulled like a steam train, cruised effortlessly in 6th on the freeway no matter the terrain and consumed THE SAME amount of fuel as our new auto mirage even though it had double the power, triple the torque and a shed load more space...

The powershift and the dealership ruined the whole ownership experience.

[Imolator]

Originally Posted by Yellow_Festiva

That is what I was told by the service Dept manager at a dealership. Ford footed the bill but had I been a regular customer apparently that is what my bill would be.

It wouldn't suprise me if they pulled that figure out of thin air, pulling a DCT out would be no more labour intensive than a manual. And the DCT clutch pack is still just a fancy clutch.

The extra work over a manual is done with a computer doing the initial clutch adjustment followed by an adaptive drive cycle, extra hour of labour tops.

There not called stealerships for nothing.....

[Yellow_Festiva]

Originally Posted by Imolator

It wouldn't suprise me if they pulled that figure out of thin air, pulling a DCT out would be no more labour intensive than a manual. And the DCT clutch pack is still just a fancy clutch.

The extra work over a manual is done with a computer doing the initial clutch adjustment followed by an adaptive drive cycle, extra hour of labour tops.

There not called stealerships for nothing.....

True that.... my original service Dept wanted $660 just to remove and inspect the transmission after waiting 2 weeks for the OK from the extended warranty mob. Would have left me with a whole $340 to go towards the repair if it was deemed a failure due to poor quality / workmanship.

[kelvinyhm]

Update:

Last weekend had a long drive of 800ks. The car had become worst. The shuddering is back though not extreme but the kluk kluk kluk sound has become worst. Almost every acceleration had the noise.

Decided to booked my car in this morning.
First thing I told them had the transmission firmware update but problem became worst than before, they REPLY is "there is nothing much we can do, its going to have this character". He told me Ford has came out with a pamphetl characteristic of the powershift and suggest I read it.

Basically told them I cannot accept this kinda problem especially it became WORST BEFORE UPDATE! They said they will try their best to redo the firmware and test drive it and if I'm not happy I'm welcome to contact Ford Australia myself.

Anyway, I left with a loan car same model (with 2500km on it) but with 50k of petrol left...sighhhh :( Driven only 5km this morning, the loan car was fantastic. No sound. No shuddering. It drives similar to conventional automatic!!

Calmed myself from this morning. Will wait till my car ready and see the result of it. To be continue....

[kelvinyhm]

Guys, need some advice here.

Service center called me moment ago told me the foreman test drive it extensively but couldn't fault anything. Plug in computer cannot find any fault code as well. Ask me to go and pick up the car.

I told the guy that it definitely have the grinding sound even the morning I drove over the service it was making loud grinding noise all the way. My wife is the one who drove it to work last few weeks and she has been complaining of loud noise during gear change.

He insisted that there is no fault reported and ask me collect car. Not sure if coincidentally its not making noise during the test or they trying to play the game. Request me to go in next day to test it with the foreman.

Problem is, every time I send the car to service center, I'll have to take time off which my boss not happy.

Assuming tomorrow if the noise not coming out when testing, what is the next course of action I can take?

I'm lost now....unhappy and frustrated. :(

[LeadFoot81]

Originally Posted by kelvinyhm

Guys, need some advice here.

Service center called me moment ago told me the foreman test drive it extensively but couldn't fault anything. Plug in computer cannot find any fault code as well. Ask me to go and pick up the car.

I told the guy that it definitely have the grinding sound even the morning I drove over the service it was making loud grinding noise all the way. My wife is the one who drove it to work last few weeks and she has been complaining of loud noise during gear change.

He insisted that there is no fault reported and ask me collect car. Not sure if coincidentally its not making noise during the test or they trying to play the game. Request me to go in next day to test it with the foreman.

Problem is, every time I send the car to service center, I'll have to take time off which my boss not happy.

Assuming tomorrow if the noise not coming out when testing, what is the next course of action I can take?

I'm lost now....unhappy and frustrated. :(

I've found that if it makes the noise, it does it consistently. Find a quiet street, have all the Windows down and try accelerating slowly so engine noise doesn't drown out the grinding sound.

I'd try to clarify if there is a disparity between what you consider normal and what the dealership considers normal re: transmission behaviors and sounds.

[SpoolMan]

Problem is the dealers have been given tolerance levels and apparently in Fords eyes because so many have an issue the tolerance some how makes it right, should the dealer fix the issue with new clutch they wont get paid unless it falls outside the tolerance level or you have to hope for the front seal to leak then they will fix asap.
Your next option is Ford Customer Relationship Centre
Phone: 13 FORD (13 3673)

We left ours at the dealers for 2 weeks whilst on holidays, my wife is on her way to pick it up now and we have been told they updated the software, I think we would be lucky if it fixes the problem from what we are all reading, we shall wait and see.
I am in Sydney until next week so I wont get a drive for a few days yet.

[kelvinyhm]

Actually it started noticeable by wife last week or two. Then she complaint it is making noise so often that I actually thought she was exaggerating. Few moments she was shocked by the noise and fear of car breaking down.

Been sensing that she might be exaggerating, I drove it last week 800ks out of town on a trip and at moments, it was making slight noise during accelerating and a few shudders (worst after program update). I was thinking...this is not good but we'll see. Sunday night, out to dinner..hmmm...slight shudder but no noise.

Monday & Tuesday...wife to work, it had it moments of kluk kluk kluk ....and wife shocked again. Decided to booked for service.

Funnily this morning while driving to service center, it was making noise most of the way (as in stop/very slow then accelerate....kluk kluk kluk kluk kluk....). No music, windows all up with AC. With driver window down (just trying to hear), gosh....it was so loud outside.

"Normal" is very subjective to individuals. Anyway finger crossed tmr morning going to test it with foreman hope the noise will be loud and clear. It will be bad if no noise during test but come up again after car is off service center.

[kelvinyhm]

Originally Posted by SpoolMan

Problem is the dealers have been given tolerance levels and apparently in Fords eyes because so many have an issue the tolerance some how makes it right, should the dealer fix the issue with new clutch they wont get paid unless it falls outside the tolerance level or you have to hope for the front seal to leak then they will fix asap.
Your next option is Ford Customer Relationship Centre
Phone: 13 FORD (13 3673)

We left ours at the dealers for 2 weeks whilst on holidays, my wife is on her way to pick it up now and we have been told they updated the software, I think we would be lucky if it fixes the problem from what we are all reading, we shall wait and see.
I am in Sydney until next week so I wont get a drive for a few days yet.

Yeah. I've created a case with Ford. Will update them after tmr.

When you take the car back, drive it for 1 or 2 weeks at least. When I took mine back after the update, it was running good for the FIRST week.

[rooford]

I had the same problem with the grinding / rattling problem, as per my previous posts, I took mine in the first time it happened and the service dept tried a software update, that made no difference, so 2nd time around a new clutch assembly was fitted and hey presto no noise.
Don't let them fob you off, if it is making the noise you describe the only way to fix it is a new clutch, Ford know there is a problem, my service centre that I bought the car from were fantastic, they said when it first happened that if the update did not work then they would put a new clutch assembly in, they did and problem fixed.
They as good as said they knew there was a problem and did not argue the point.

[kelvinyhm]

Well this morning went back into service center. Met up with manager and explained to me blah blah about characteristic and the procedure they have to follow before notifying Ford to get something replace.

Met up with foreman, same stories. Explained to me about the procedural of test with certain threshold before sending result to Ford. Cut short..we went for test drive in my car.

Here goes...foreman drive me passenger...

First turn out of car park...no shudder no noise. Second turn, no shudder slight noise. Almost every turn after that sometimes shudder but always has noise. Test uphill start stop, bad shudder and noise.

Now here came my side of defend for my opinion to him...
- reading Ford common characteristic of powershift, does the foreman think this is acceptable level of grinding noise and shudder?
- the loan car same model with powershift was running perfect...and I mean PERFECT! Not even a slight shudder or noise. Explain that??

Test finished. He spoke to manager. Foreman reckon to change clutch pack and try his best to recalibrate and tune etc to minimise the noise. To call me when car ready.

Thank you bye bye and off me to work with loan car.

[SpoolMan]

Thats when you realise how bad the issue is when you drive another car, this week I drove a hired Toyota Yaris for 24 hrs and the auto was gold, smooth and directly on the power when you put your foot down.

[Hawkeye84]

Im noticing that the gearbox issues are prevalent in the petrol Trend, Sport & Titanium models (those with the 2.0L engine).

Are people experiencing the same issues with the powershift transmission when it is mated with the petrol 1.6L Engine in the Ambiente?

[kelvinyhm]

Originally Posted by Hawkeye84

Im noticing that the gearbox issues are prevalent in the petrol Trend, Sport & Titanium models (those with the 2.0L engine).

Are people experiencing the same issues with the powershift transmission when it is mated with the petrol 1.6L Engine in the Ambiente?

I have seen people complaining it happened to Fiesta powershift too which I assumed its the same engine as Focus 1.6 Ambiente.

[kenchow]

Originally Posted by Hawkeye84

Im noticing that the gearbox issues are prevalent in the petrol Trend, Sport & Titanium models (those with the 2.0L engine).

Are people experiencing the same issues with the powershift transmission when it is mated with the petrol 1.6L Engine in the Ambiente?

I have the 1.6 but just a bit jerky before 5k (probably not run in) but now is smooth. I wonder if it is due to the 2.0 has more torque that the transmission unit to handle. One thing is not to expect it has the same characteristic as the traditional auto. Try use the sport mode which has a better result in slow traffic.

[Imolator]

Originally Posted by kenchow

I have the 1.6 but just a bit jerky before 5k (probably not run in) but now is smooth. I wonder if it is due to the 2.0 has more torque that the transmission unit to handle. .

The Ford DCT is designed by Getrag and its model name is the DCT250, its designed supposedly to handle up to 250nm of torque.

As the 2.0 Focus only puts out 202nm of torque it shouldnt be an issue.

I dont think these transmissions in D are suited to big city stop start traffic if driven the same way as normal auto drivers do. ie you cant let them creep along repeatedly as that is slipping the clutch.

In traffic I always use select shift, and I never let the car creep along. If the car in front creeps forward a couple of feet and stops I dont.

I dont believe that this type of transmission is suitable for someone who has only ever driven automatics, you can creep an auto along in stop start traffic and that is just what auto drivers get used to doing.

You cant do that in these boxes.

[In Focus]

Yes, I agree. It's the same with VW DSG. Strangely, I'd imagine people who are used to a manual rather than a "conventional" automatic will adapt more quickly to a DCT.

[christianj]

Originally Posted by kelvinyhm

I have seen people complaining it happened to Fiesta powershift too which I assumed its the same engine as Focus 1.6 Ambiente.

I was in Brisbane last month and had a 1.6 Focus as the rental car and the shudder was horrendous.

Our 2.0 focus went in yesterday and they have agreed to order the new modified clutch kit for it and will replace ours once it comes in.

If there is no issue with these why have they modified the clutch kit to fix the problem.

Previous to this we had a golf with DSG and had to have the clutch replaced on that too which rectified it's shudders and made it nice to drive again.

[christianj]

Just thought I'd add to this that my Kuga diesel has the powershift & my driving style in that and the focus is the same - I get shudder in the Focus & smooth and refined in the Kuga.

I think this is the difference between the wet & the dry powershift