I came back here to say thanks to all the contributors here especially
@MK3_Focus_PS.
A bit of history, I grew up in a family of mechanics, doing engine and trans swaps, motor rebuilds and regular maintenance was just something we always did. My son ( a senior in highschool at the time) purchased his first car, a 2014 Focus hatchback titanium. Very nice car. I didn’t know much about the Focus’ but learned quick that the auto transmissions have some issues. About 6 months in we experienced a trans failure, a bit different than the DCT issues most people have. There was an internal housing issue and some of the casting broke internally and the trans wouldn’t shift out of 1st gear. Long story short we started looking at replacement options. The easy thing would have been finding an Auto trans for a replacement. I stumbled across this thread about the same time my son found
@MK3_Focus_PS videos on YouTube. This thread gave us the confidence to proceed.
We found a local 2015 donor vehicle at a local salvage yard. Printed off the list of needed parts and the guy at the salvage yard, once he found out what we were looking to accomplish, gave us all the needed parts including the manual ecu for around $550. A weekend of wrenching, a borrowed J2534 adapter from my local mechanic friend and a FDRS license, ForScan and an Elm327 adapter later, we have a fully functional, almost ‘stock’ manual titanium hatchback. My son and I learned a ton and even though we made some mistakes (we bricked the first ECU) there are a few things I would recommend.
1. Find a good donor car. This made things super handy 1 stop for all our parts.
2. Do it right. After we botched the first ecu, we ran it for a while on the auto ecm but that got old fast and while the rev limited might be able to be removed with a tune, the manual ecu swap and program was actually easier than expected once we followed the instructions properly.
3. Replace the seals in your acquired trans. I knew better but failed to order new ones and decided to risk it. We now have an oil leak we need to deal with yet (probably when my son melts his first clutch) but we’ll see. I’m getting tired of the drips on the driveway.
4. ForScan made it super easy to ‘delete’ the unnecessary auto stuff that the BCM was looking for and was throwing either nuisance warnings for or actual CEL/Codes. Hill start assist, traction control, removing the PRNDL dash info, and a few more items. I also updated the BCM clusters reflect the manual trans and while the ECU module programming reflected a manual with the correct vin, the BCM wasn’t aware of the change until we manually changed it.
5. For some reason (we didn’t find any documented cases of this) the ABS sensor(s) were throwing codes. I did an ABS reset and so far after several hundred miles it hasn’t re-occurred.
Again, thanks all for the detail info above. It certainly helped us be successful and I’d likely do it again given the need to do so.