🔧Ford Focus DCT Transmission Diagnosis - DCT DPS6

*Ford Focus DPS6 Transmission Diagnostic*

*Subject:* Analysis of a Ford Focus with a Dual-Clutch Transmission (DCT) Issue

*Initial Problem & Symptoms*
**Noise from Transmission**: A concerning noise from the transmission area.
*Recent TCM Replacement**: The vehicle has a *new TCM, but the issue persists.
*Fault Codes:* Multiple fault codes, with "transmission friction element A stuck on clutch a stuck engaged" being the primary code.
*Transmission Behavior:* Vehicle appears stuck in high gear, unable to engage gears or move in reverse or drive.

*Diagnostic Process*
*Initial Data Review:* Mechanic reviews input/output shaft speeds, and clutch actuator positions. Clutch A motor behavior is suspect.
*Transmission Adaptation:* Attempted TCM learning causes noise to temporarily disappear, confirming the issue is within the transmission and not the TCM.
*Clutch Touch Point Learning:* Clutch adaptation tests fail, indicating a serious mechanical issue.
*Actuator Motor Inspection:* Mechanic inspects clutch actuator motors, finding a problematic fork. Manual attempts to open the clutch fork fail, suggesting it is “stripped out”.
*Motor Swapping:* Swapping the positions of the actuator motors does not fix the problem.
*Re-testing & Partial Success:* After swapping the motors, the clutch travel tests pass. The sound of the clutches are heard, indicating the motors are probably okay. This means the underlying mechanical issue with the fork is the problem.

*Key Findings*
**Mechanical Issue**: The root cause is a mechanical problem, specifically a damaged or stripped clutch engagement fork associated with "Clutch A".
*Suspect Fork:* The fork that moves the throw-out bearing is likely damaged, preventing clutch engagement.
*Motor Function**: Actuator motors are *likely functioning but can't compensate for fork damage.
*Common Issue:* Damaged forks are a "common" issue in these units.

*Proposed Solution and Best Practices*
**Transmission Removal**: The transmission needs to be removed for repair.
**Clutch Replacement**: A clutch replacement is advised at the same time as repairing the fork.
**Complete Component Replacement**: Standard practice is to replace the clutch, both motors, and both forks to prevent future issues.
*Ground Cleaning:* Clean ground connections under the battery and apply protective paint to improve electrical connections.

*Conclusion*
The Ford Focus dual-clutch transmission has a mechanical fault, likely a stripped clutch engagement fork. The recommended action is to remove the transmission, and replace the clutch, both motors, and both shift forks. The diagnostic process highlights the importance of thorough testing, mechanical knowledge, and understanding common issues associated with specific vehicle models.

Tags: Ford Focus, DCT, Transmission, Diagnosis, Repair, DPS6, Dual-Clutch, TCM, Clutch, Actuator, Shift Fork

#FordFocus, #DCT, #TransmissionRepair, #CarTroubles, #MechanicLife,