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Mostly sounds like a major TCM failure but good that you're getting the full work over before your extended warranty expires. I'm out of warranty on the clutch due to mileage and age of the vehicle but I had 3 clutches installed under warranty and one TCM replaced. When my TCM went bad it was abrupt in the middle of my commute and it left me stranded (wouldn't start) so I had to have it towed to the dealer. There's supposed to be a class action payout if you've had enough failures but it's a pittance and they sure are taking theme is time with it. As usual, the lawyers are the only ones who really benefit.

Best of luck with yours.
 

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Transmission failure at 54k miles... Ford should be ashamed.
Actually not transmission failure per se, just needed new clutchpacks, they put in the most recent revision (as of May, 2018) and they claim out of a whole bunch done, not one has come back yet with any more issues...car is driving great again, I had shudder for a long time but was not sure because it started around same time I installed TTR drivers side mount and some people claim it's caused a buzzing noise...I feel silly for not knowing it was shudder (although I have 3 aftermarket motor mounts so the entire car is a buzzin')..but I should have known, the shudder felt the same as my '96 sunfire when the 4T40E transmission was not locking the torque converter properly..same sensation.

At the same time they replaced my input shaft seals, which were black and older and prone to leaks, they had to ask Ford for permission to do so, it made sense since the leaking seals eventually would cause clutchpack issue or transmission failure..they were replaced with newer "brown" input shaft seals... it's quite a list, i'll upload the workorder, I got all new fluid of course having to remove the transmission...they had to shampoo the engine as there was substantial clutchpack "material" built up off the transmission and onto part of engine..and on and on. I hope the dct can last another 86,000km or more as long as I continue to drive it in a manner that will help.

At this point im wondering if I should sell it and move into something different or keep it as I have some bucks invested in wheels, performance and suspenstion stuff (list keeps growing).. I have about 1.5 years left on extended warranty, further issues if they happen will likely be after this expires and then I could be looking at substantial bill to repair
 

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Found On Road Dead (Again)..2 days after the DCT work, car was screwed again.. bucking and surging like crazy, was very dangerous and happened while I was on a highway, almost caused a pileup thanks to people tailgating me at highway speeds when transmission would not upshift so I was stuck in 2nd gear only allowing me to go about 60km/hour..pulled over, had to get it towed to dealership.. got a loaner and quick email an hour later that car was done, I called them up and they said my TCM went now... so on Tues, new clutchpacks, seals, fluid, etc etc... today new TCM.. WHAT else can go wrong, yes I'm going there.

Anyone know if Ford care will pay for the towing, mileage fees? ($200) My 1.5 days of missed work ($225)..dealer said to call fordcare about those expenses and that they have no part of that and could not confirm if they will be covered.
 

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Found On Road Dead (Again)..2 days after the DCT work, car was screwed again.. bucking and surging like crazy, was very dangerous and happened while I was on a highway, almost caused a pileup thanks to people tailgating me at highway speeds when transmission would not upshift so I was stuck in 2nd gear only allowing me to go about 60km/hour..pulled over, had to get it towed to dealership.. got a loaner and quick email an hour later that car was done, I called them up and they said my TCM went now... so on Tues, new clutchpacks, seals, fluid, etc etc... today new TCM.. WHAT else can go wrong, yes I'm going there.

Anyone know if Ford care will pay for the towing, mileage fees? ($200) My 1.5 days of missed work ($225)..dealer said to call fordcare about those expenses and that they have no part of that and could not confirm if they will be covered.
Yeah, I'm thinking they should have recognized that the original behavior you were describing was most likely due to the TCM going bad. Not saying it didn't need a new clutch and seals but those usually just exhibit the shudder when they are going bad. The when the TCM goes bad it's basically the computer that controlls all the shifting getting fried so if it's out of commision, you're not going anywhere. I would complain to Ford Care that the dealer should have known this. With all their diagnostic equipment, they should be able to do better than a guy on the internet who hasn't even touched the car.
 

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Yeah, I'm thinking they should have recognized that the original behavior you were describing was most likely due to the TCM going bad. Not saying it didn't need a new clutch and seals but those usually just exhibit the shudder when they are going bad. The when the TCM goes bad it's basically the computer that controlls all the shifting getting fried so if it's out of commision, you're not going anywhere. I would complain to Ford Care that the dealer should have known this. With all their diagnostic equipment, they should be able to do better than a guy on the internet who hasn't even touched the car.
[hihi] I did push for them to replace the TCM and listed the behaviors present during 2nd breakdown, they could not find any codes related and for some strange reason that behavior was not happening the 3rd time I started car and did a testdrive, so when the car went to dealer they only had the shuddering and said they could only replace the TCM if the above conditions present...this is part of the problem with Ford's handling of this issue, they force people to go back to dealer many times and this forces their hand to get rid of the cars and have a terrible experience, ie: Never buying ford again, etc etc.

At this point im not sure what Im going to do, have money invested in the car and a fair amount of parts... should I put back to stock, and sell it while it still has a year of extended warranty, or roll the dice and likely have future dct failures and have to fix on my dime. [:(]
 

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[hihi] I did push for them to replace the TCM and listed the behaviors present during 2nd breakdown, they could not find any codes related and for some strange reason that behavior was not happening the 3rd time I started car and did a testdrive, so when the car went to dealer they only had the shuddering and said they could only replace the TCM if the above conditions present...this is part of the problem with Ford's handling of this issue, they force people to go back to dealer many times and this forces their hand to get rid of the cars and have a terrible experience, ie: Never buying ford again, etc etc.

At this point im not sure what Im going to do, have money invested in the car and a fair amount of parts... should I put back to stock, and sell it while it still has a year of extended warranty, or roll the dice and likely have future dct failures and have to fix on my dime. [:(]
Sounds like you have a bad dealer. I am surprised that the goofy stuff your transmission was doing didn't throw a single persistent code but even so, if they believed your description of what was going on, almost none of that could have been caused by a slipping clutch. It had to be something in the shift control system, i.e., the TCM. When my TCM went out, it ended up shutting everything down and the car wouldn't even start. I had to have it towed but somehow these things can still "reset" themselves over time as the dealer was able to start up the car after it was towed to them. When I was stranded, the first thing I did was to disconnect the battery for a while hoping to force some sort of reset but this didn't work.
 

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... I am surprised that the goofy stuff your transmission was doing didn't throw a single persistent code ...

... When my TCM went out, it ended up shutting everything down and the car wouldn't even start. I had to have it towed but somehow these things can still "reset" themselves over time as the dealer was able to start up the car after it was towed to them. ...
It is good that it tries to regain some ability to function again whenever possible, but to fail and not record some permanent record of that event is bad software design. That's especially true now that the people repairing them have become so depedent on the computers to do all the troubleshooting for them. (Even the ones who still have some troubleshooting skills are discouraged from using them.)

Software designers I have worked with would point to hardware and claim there's nothing they could do when the hardware their software depended on to run failed (which is likely the case with malfunctioning TCUs). Sometimes I managed to convince them it was worth the effort to make their software smart enough to show proof when it could not do its job due to a hardware failure so the repair guys would not blame their software.

Ford has probably calculated that it's cheaper to just put it back on their customers until the failure is complete than do the extra R&D. Kinda' hard to calculate the value of lost future sales, but sales of Honda Civics and Toyota Corollas probably benefit from that.
 

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Ford has probably calculated that it's cheaper to just put it back on their customers until the failure is complete than do the extra R&D. Kinda' hard to calculate the value of lost future sales, but sales of Honda Civics and Toyota Corollas probably benefit from that.
I think this DCT disaster was part of the reason they decided to not make cars anymore, not just focus but fiesta and other vehicles that used it.
 

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But the Focus is still being made? [poke]
It is still being made in Germany and China because the market for sedans in Europe and Asia are still more profiteable I imagine.

I wonder had they produced the Mk. III Focus in the same quality as the Mk. II Focus they would have been able to sell more of them, given the 2008 MSRP was $14,755 and the 2012 MSRP being $16,500. People who buy the Focus are very price-conscious IMO.
 

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It is still being made in Germany and China because the market for sedans in Europe and Asia are still more profiteable I imagine.

I wonder had they produced the Mk. III Focus in the same quality as the Mk. II Focus they would have been able to sell more of them, given the 2008 MSRP was $14,755 and the 2012 MSRP being $16,500. People who buy the Focus are very price-conscious IMO.
How many of the Foci in Germany and China have manual transmissions? Maybe they avoided the bad rep that the DCT gave them over here in the US because they were mostly selling sticks?
 

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How many of the Foci in Germany and China have manual transmissions? Maybe they avoided the bad rep that the DCT gave them over here in the US because they were mostly selling sticks?
I don't know about Europe but for all the times I've been to China it seems that most of the Focuses are DCT-equipped, albeit a wet-DCT instead.

From what I know European and Asian market Focuses uses the wet-DCT transmission while our market here uses the dry-DCT. I think wet-DCTs are known for having to do regular fluid changes but do last longer while dry-DCTs are more mechanically simpler but wears out the clutch faster especially in heavy urban traffic.

Beats me why a DCT is used instead of a torque converter automatic or CVT for Ford...in the meantime, there is a really good post about the DCT here:

https://www.focusfanatics.com/forum/mk3-focus/415994-ford-powershift-dct-transmission-info-use-guide-new-owners-look-here.html#/topics/415994?page=1&_k=q3j0y8
 

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I don't know about Europe but for all the times I've been to China it seems that most of the Focuses are DCT-equipped, albeit a wet-DCT instead.

From what I know European and Asian market Focuses uses the wet-DCT transmission while our market here uses the dry-DCT. I think wet-DCTs are known for having to do regular fluid changes but do last longer while dry-DCTs are more mechanically simpler but wears out the clutch faster especially in heavy urban traffic.

Beats me why a DCT is used instead of a torque converter automatic or CVT for Ford...in the meantime, there is a really good post about the DCT here:

https://www.focusfanatics.com/forum/mk3-focus/415994-ford-powershift-dct-transmission-info-use-guide-new-owners-look-here.html#/topics/415994?page=1&_k=q3j0y8
Thanks for that info, I did not know that Focus's over there had wet DCT's. So someone at Ford looked at the dry vs wet DCT's and decided that oversees the dry DCT wouldn't cut it. I'd love to know what the tipping point was on that decision.

I also drive a 2002 Focus with a hydraulic auto... That car just passed 250k miles and it still drives great. The tradeoff... it only gets 26mpg whereas my 2015 averages 38. Plus the 2002 is significantly less fun to drive!

I've done a little work on the 2002's transmission too, so it hasn't been entirely maintenance free. A couple of the shift solenoids have went out, those were pretty cheap and easy to replace myself. Also had the high pressure line blow off its fitting one winter, sprayed all of the trans fluid down the road until it stopped pulling :). No harm though, new line and fluid and good as new :).
 

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I don't know about Europe but for all the times I've been to China it seems that most of the Focuses are DCT-equipped, albeit a wet-DCT instead.

From what I know European and Asian market Focuses uses the wet-DCT transmission while our market here uses the dry-DCT. I think wet-DCTs are known for having to do regular fluid changes but do last longer while dry-DCTs are more mechanically simpler but wears out the clutch faster especially in heavy urban traffic.

Beats me why a DCT is used instead of a torque converter automatic or CVT for Ford...in the meantime, there is a really good post about the DCT here:

https://www.focusfanatics.com/forum/mk3-focus/415994-ford-powershift-dct-transmission-info-use-guide-new-owners-look-here.html#/topics/415994?page=1&_k=q3j0y8
Thanks for that info, I did not know that Focus's over there had wet DCT's. So someone at Ford looked at the dry vs wet DCT's and decided that oversees the dry DCT wouldn't cut it. I'd love to know what the tipping point was on that decision.

I also drive a 2002 Focus with a hydraulic auto... That car just passed 250k miles and it still drives great. The tradeoff... it only gets 26mpg whereas my 2015 averages 38. Plus the 2002 is significantly less fun to drive!

I've done a little work on the 2002's transmission too, so it hasn't been entirely maintenance free. A couple of the shift solenoids have went out, those were pretty cheap and easy to replace myself. Also had the high pressure line blow off its fitting one winter, sprayed all of the trans fluid down the road until it stopped pulling :). No harm though, new line and fluid and good as new :).
Most of the lower powered gas engines had the dry DCT over there (1.6L NA, 2.0L GDI, etc), only the higher torque output turbo diesels had the wet clutch DCT as an option.
 

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In Europe, Ford currently offers a PowerShift transmission in the Ford Focus. This PowerShift uses a twin wet-clutch system to handle the higher torque levels of the 2.0-liter TDCI engine available in the Focus.
It says the 2.0L TDCI engine which is the diesel used a wet clutch version of the DCT, but not that all European models only used the wet clutch. so that doesn't contradict what I said at all. That was one of the only versions to get the wet dual clutch, which were the high output diesels.

The lowest output NA petrols were available with the dry dual clutch DPS6 like the 1.6L Ti-VCT like the Fiesta powertrain here. but the 1.5L TDCI and other higher torque output engines had the wet clutch, and the 1.0L EcoBoost has the 6F15.
 

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Most of the lower powered gas engines had the dry DCT over there (1.6L NA, 2.0L GDI, etc), only the higher torque output turbo diesels had the wet clutch DCT as an option.
It says the 2.0L TDCI engine which is the diesel used a wet clutch version of the DCT, but not that all European models only used the wet clutch. so that doesn't contradict what I said at all. That was one of the only versions to get the wet dual clutch, which were the high output diesels.

The lowest output NA petrols were available with the dry dual clutch DPS6 like the 1.6L Ti-VCT like the Fiesta powertrain here. but the 1.5L TDCI and other higher torque output engines had the wet clutch, and the 1.0L EcoBoost has the 6F15.
https://www.youtube.com/watch?v=viIaQiuyfTY
I stand corrected. Thanks for clarifying!

I do find it surprising that I haven't heard much complaints from the other side of the pond though
 

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Add my car to the DCT Clutch Replacement Club.

2016 Focus SE Hatchback.
32,500 miles

Usual 1st gear shuddering had increased.
Under full throttle acceleration (like entering a freeway on ramp) the 1st to 2nd shift was very slow and sloppy. If I was driving a stick it would be like slipping the clutch in and out of gear. No clean gear changing.
After hard acceleration I could smell the clutch inside the car cabin.

Ford:
Perform Diagnosis and Pin Point test (clutch out of spec)
Replaced clutch assembly, seals, oil, update pcm and tcm.

Cars seems to work ok now... I'll see how it holds up over time.
 

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This mega-thread started in 2014, and now we are seeing 2016 cars with the issue. Crazy

What the hell are Ford thinking?
This one issue on the Focus with the DCT transmission is the most egregious act by an auto company that I have ever seen. I was lucky to see a trend in the posts and get rid of mine early, before the issue became widely known. I got a good trade-in value plus a good deal on a Mazda-3 back then. But there are many people here who were underwater on their loans and did not have that option. So they became mired in an endless cycle of getting danced around by the dealer, leaving it for repair and hardly always getting a loaner. Now it became time off of work in addition to being underwater on the loan.
I once had a young service writer hand me that "you're driving it wrong memo" and after a few questions, i found he couldn't ever explain what DCT was.
I have owned 2 mustangs, 3 escorts, an F150 and they have all been GREAT.
I have read and posted here for over 5 years and watched these boards go from saying its a rare problem and folks are making too much fuss, then they started saying ok but its a small percent of production, then ford began to hand out "you're driving it wrong" memos at the service departments, which led to people forming their own threads here, to tell you how to drive it properly ....to your post today.

I have lost track of how many people got the first fix but they were back within several weeks to months, saying the problem(s) had come back.

Additionally there was the snorkel delete and the WOT suggestions. Again why should you have do be under the hood removing parts or doing Wide Open Throttle starts to get your car to shift properly?

As I have noted before you can hop in any vw or audi with a dual clutch transmission and experience NONE of the issues that Ford (and its defenders) said were "normal". Other Ford defenders were quick to point out that vw-audi is a "wet" dual clutch so not the same, and I would counter with - I am not aware of "any" dry dual clutch cars/brands where owners are happy. It possibly should never have been built.
Tom's tune has tried to help out with mostly success stories but why in the world should you have to do that ? (no disrespect to Tom's hard work and results)
The ford customer service reps who tried to help out the accellerating numbers of complaints here have been gone for over a year.
WE all work hard for our money and this has been outrageous.
yet, go to any major car show and you can see dual clutch trannies (wet) in Nissan GTR, yesterday I saw one in a McLaren, ferraris' you name it

last but not least there was a contingent here who came forward to say their DCT was working great, yet months to years later they came back and guess what? same problem(s)

The point of this very long ramble is Ford should be made to pay for all this. If you had any less expensive device this balky, you'd just drive it back to the store and get a refund
 
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