2011 MC Mondeo Titanium Powershift Clutch Replaced

[medievil]

Hi all,
Looking for some basic help on how a powershift gearbox works and if the twin clutch unit has been replaced, is there any chance of anything else being wrong or damage being done to other parts and should I keep an eye or ear out for signs of it.

At approx 42k on the speedo, my 2011 built, bought 2012 June (thank the almighty) car has just been returned to me with the clutch unit replaced. The dealer service here in Brisbane has been awesome in dealing with me and has kept me informed along the whole process.

About three weeks ago it was diagnosed as being the clutch unit with slipping in 3rd and surging under load in 3rd. Last week I let the dealer service know that I had also noticed that it had become quite jerky from a stop and I was worried that my once smooth car would strand me somewhere with a failure. I could also here noise increasing with the surging (pulsing) and the shuddering had increased.

The dealer service had the part but hadn't received the specialised tools yet to open the box so they were going to pull the box out and send it somewhere else to do the clutch replacement. I dropped it off Monday and got it back Wednesday afternoon. All fixed.

Now, all I have been told is that both clutches are in the one unit and they know it was faulty but did not pull it apart (or couldn't?) to ascertain what had failed. After driving the car, everything seems back to normal.

This is by far my favourite car to have owned/driven and I do look forward to having a drive of the new one later this year or next.

The one thing that this failure did was make me finally ring and extend the Ford Australia New Car warranty. Money well spent, the more I look into the problems with dual clutch type gearboxes. I shudder to think what this would have costed had it not been under warranty.

Cheers

[VF69HARDTOP]

Glad you got it fixed under warranty. I know two Ford mechanics and when I was looking for my Mondeo, they both told me straight up "don't buy one with a power shift trans"
Armed with this, I bought a 2009 diesel zetec. My mother inlaw has a Fiesta that had the clutches replaced a couple weeks ago also.

[cobrin]

Originally Posted by VF69HARDTOP

Armed with this, I bought a 2009 diesel zetec.

lol so did I. 12mths ago.

I have a few niggly issues to sort out to bring it back up to scratch but engine and trans wise it's A1.

[cyclone1410]

Originally Posted by medievil

At approx 42k on the speedo, my 2011 built, bought 2012 June (thank the almighty) car has just been returned to me with the clutch unit replaced. The dealer service here in Brisbane has been awesome in dealing with me and has kept me informed along the whole process.

Cheers

Which Brisbane Dealer was it?

[medievil]

Originally Posted by cyclone1410

Which Brisbane Dealer was it?

Moreton Bay Ford, Mansfield

Cheers

[Binny]

Originally Posted by medievil

Hi all,
Looking for some basic help on how a powershift gearbox works and if the twin clutch unit has been replaced, is there any chance of anything else being wrong or damage being done to other parts and should I keep an eye or ear out for signs of it.

At approx 42k on the speedo, my 2011 built, bought 2012 June (thank the almighty) car has just been returned to me with the clutch unit replaced. The dealer service here in Brisbane has been awesome in dealing with me and has kept me informed along the whole process.

About three weeks ago it was diagnosed as being the clutch unit with slipping in 3rd and surging under load in 3rd. Last week I let the dealer service know that I had also noticed that it had become quite jerky from a stop and I was worried that my once smooth car would strand me somewhere with a failure. I could also here noise increasing with the surging (pulsing) and the shuddering had increased.

The dealer service had the part but hadn't received the specialised tools yet to open the box so they were going to pull the box out and send it somewhere else to do the clutch replacement. I dropped it off Monday and got it back Wednesday afternoon. All fixed.

Now, all I have been told is that both clutches are in the one unit and they know it was faulty but did not pull it apart (or couldn't?) to ascertain what had failed. After driving the car, everything seems back to normal.

This is by far my favourite car to have owned/driven and I do look forward to having a drive of the new one later this year or next.

The one thing that this failure did was make me finally ring and extend the Ford Australia New Car warranty. Money well spent, the more I look into the problems with dual clutch type gearboxes. I shudder to think what this would have costed had it not been under warranty.

Cheers

Sorry to hear you had issues with yours. I bet you're glad it was still under warranty. The extended factory warranty will be good peace of mind. I did the same thing. I have 2.5 years to go so whether I need it in that time will determine if I keep the car any longer I guess.
To answer your question this youtube video is the best way to show you.
https://www.youtube.com/watch?v=YVJnNPbjjjs

He takes the clutch unit out at about the 6min mark. You can see how it is an enclosed unit with concentric shafts through it (one shaft inside the other).
I found this video really interesting. Its amazing engineering.
NOTE - its for a dry clutch Focus but the wet clutch design is similar. Once he takes the clutch pack out he points out the dodgy oil seal that is the cause of most dramas with the Focus and Fiesta. Its a good visual explanation as to why the Mondeo Powershift doesn't have the same issues because the whole clutch is in a bath of oil like in a motorbike so an oil leak into it is not going to make any difference to its operation.

[GK]

Great video. Very informative.

Cheers,

GK

[medievil]

I have been meaning to get here and thank Binny for the awesome link and info.

Cars are such funny things to people. I was showing one of the guys at work this video explaining what was playing up. He has a Focus 2013 Trend and just thought the shudder he had increasing from the car was something he would alert them to at next service. He then thought about how bad it seemed and sure enough it has fallen victim to the leak and shudder. Ford Etis site also supported that the gearbox on his has outstanding field service items. He honestly just thought it was the way it was and would need adjusting at service.

[mik]

2nd time i have watched this video, on the vehicles with these transmissions without all the special gear/tools, the do it your selfer would be banging his head up against the wall at every turn, the days of do it yourself and cheap repairs are coming to an end on a lot of cars these days..

[Binny]

Originally Posted by mik

2nd time i have watched this video, on the vehicles with these transmissions without all the special gear/tools, the do it your selfer would be banging his head up against the wall at every turn, the days of do it yourself and cheap repairs are coming to an end on a lot of cars these days..

For sure. Especially with the engines themselves. Now petrol engines have caught up with diesel as far as common rail direct injection, high compression and turbos, they are more complicated than ever. All the anti diesel brigades rhetoric about the cost of repairing them is becoming irrelevant as petrol engines are now the same. The only difference is the particulate filter and that may change as well. I have read a few articles about how petrol engines with the above tech can produce the same amount of particulate as diesels. Its on the Internet though so grain of salt required.

I remember many years ago when my XF ute needed a rebuild I bought a factory service manual and a rebuild kit and did it myself. I had never done anything like it before so it was a great learning experience.
You couldn't do that now, the complication and cost of tools would be too prohibitive.