Tài liệu hộp số xe ô tô FORD FOCUS và FORD FIESTA

6DCT250 HOP SO POWERSHIP FOCUS-FIESTA SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Specifications Transmission fluid WSS-M2C200-D2

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Transmission fluid - Dry 1.8

Transmission fluid - Service 1.5

(0.029-0.049) Clearance between 1st/5th gear shift fork and hub sleeve

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Standard 0.75-1.25

(0.029-0.049) Clearance between 3rd gear shift fork and hub sleeve

(0.024-0.044) Clearance between 2nd/6th gear shift fork and hub sleeve

(0.024-0.044) Synchronizer ring clearance, clearance between synchronizer ring

and flank surface of gear

Differential Shim Selection Chart

Tool reading mm (in) Shim Thickness mm (in)

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Gear Ratio Final Drive Overall Ratio

to simultaneously select the next gear up or down depending on shift direction, providing seamless shifting through the 6 forward gears Gear selection is controlled by the TCM using two integrated electric motors to rotate a series of gears and shift drums which in turn move the shift forks selecting the appropriate gear The TCM utilizes a number of sensors mounted

on the transmission and data received via the CAN to maintain the correct operation of the transmission

Transmission Description — Component Location

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Item Description

1 Transmission Vent Assembly

2 Transmission Clutch Actuator Motor #1

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6 Transmission Halfshaft Seal

7 Transmission OSS Sensor

8 Transmission ISS Sensor #1

9 Transmission ISS Sensor #2

10 Transmission Clutch Actuator Motor #2

Comments:

Gears 2nd, 4th, 6th and R

1 Transmission Fill Plug

2 Transmission Drain Plug

3 Transmission Halfshaft Seal

Transmission Description — System Operation and Component Description

System Operation

Overview

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1 Engine

2 Clutch unit

3 3rd, 4th, reverse and park gear output shaft

4 Input shaft (solid shaft) (1st, 3rd, 5th)

5 1st, 2nd, 5th and 6th gear output shaft

6 Differential

7 Input shaft (hollow shaft) (2nd, 4th, 6th, R)

In principle, the transaxle comprises two independent gear trains

During driving, one gear train is always positively connected and the other set is already engaged in the oncoming gear (although the clutch for this gear is still open)

Transaxle Design

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1 Input shaft (solid shaft) (1st, 3rd, 5th)

2 Output shaft (3rd, 4th, R and Park)

3 Differential

4 Final drive / ring gear

5 Input shaft (hollow shaft) (2nd, 4th, 6th and R)

6 Output shaft (1st, 2nd, 5th and 6th gear)

The name 6DCT250 stands for:

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Ford is installing the transaxle for the first time in the Fiesta (B299), model year 2010.5 (04/2010-) with 1.6L Duratec engine It will be used universally in further vehicle lines

The transaxle features two nested input shafts driven by a compact dry dual clutch system These two shafts are used in concert to provide seamless shifting through the six available ratios with overdrive in the two top gears

As each gear is selected, the appropriate clutch is activated to drive the vehicle Each

consecutive gear is then preselected for the next "shift" operation as power is shifted from one clutch to the other and back again whilst moving up and down through the individual gears

The 6DCT250 transaxle provides the smooth application of power as per the 6DCT450, but with the advantages in efficiencies found only in a manual transaxle By delivering power with a dual "dry" clutch system, fluid volume is limited to less than 2 litres as compared to the conventional automatic transmission

The actuation of the clutch system is controlled by a dedicated computer through two

individual electronically driven clutch motor and actuator systems

The selector lever has the following functions:

 P - Park position

 R - Reverse position

 N - Neutral position

 D - Electronic control of the transmission ratio using the TCM (Transmission Control Module)

If the selector lever is in the "P" position and the vehicle has been switched off, first gear and reverse gear will be engaged via the TCM

This results in a faster response after the starting process

Special features of the transmission include:

 6 gears plus reverse gear

 Compact front transverse installation

 Dry clutch

 Internal electronic gearshift mechanism

 Intelligent gear change control

Specification

Description Ford PowerShift (6DCT250)

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Rotational torque 250 Nm

Gears Six forward gears, one reverse gear

Fluid specification WSS-M2C200-D2 (BOT350-M3)

World Manufacturer GETRAG Transmission GmbH

Dual Clutch Design

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released steps are at the required torque capacity and within the required time

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7 Input shaft spline (solid shaft)

8 Input shaft spline (hollow shaft)

9 Friction disk

Operating principle of the transaxle

With the dual-clutch transaxle, gear (ratios) are engaged through the use of a dual multi-plate clutch in combination with electro-hydraulic controls

One of the multi-plate clutches is engaged in driving mode, the other is open allowing selection of the next gear ratio

pre-The clutch of the previously activated gear opens according to the accelerator pedal position and request by the driver and simultaneously closes the other clutch in order to engage the preselected gear

The illustration shows the gearshift process in a manual transaxle

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NOTE: When looking at the illustrations, please note that the torque flows from the input

shaft once via the solid shaft and one via the hollow shaft

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1st Gear

The torque is introduced into the dual clutch via the flywheel From there, the power is

transmitted via clutch 1 to the input shaft (solid shaft) The input shaft transmits the torque

to the first gear of the output shaft The torque is transmitted to the differential via the output pinion

2nd Gear

transmitted via clutch 2 to the input shaft (hollow shaft) The input shaft transmits the torque

to the second gear of the output shaft The torque is transmitted to the differential via the output pinion

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3rd Gear

to the third gear of the output shaft The torque is transmitted to the differential via the output pinion

4th Gear

to the fourth gear of the output shaft The torque is transmitted to the differential via the output pinion

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5th Gear

to the fifth gear of the output shaft The torque is transmitted to the differential via the output pinion

6th Gear

to the sixth gear of the output shaft The torque is transmitted to the differential via the output pinion

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Reverse

transmitted via clutch 2 to the input shaft (hollow shaft) The input shaft now transmits the

torque to the reverse/2nd double gear which acts as an idler gear to reverse the direction of rotation, this idler transmits torque to the reverse gear of the output shaft The torque is transmitted to the differential via the output pinion

Park System

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3 Torsion spring

There is a parking lock integrated in the second output shaft for safe parking of the vehicle and to prevent it from rolling away when the parking brake is not applied

The parking lock needs to be installed since the clutch actuators are not actuated when the engine is switched off The absence of power to the clutch actuators means that both clutches are in the open position (normally open system)

Engagement on the park lock pawl (5) takes place exclusively by mechanical means A gearshift cable actuates the actuation shaft (2) when the transmission is placed into Park "P" position via the selector lever This causes the park lock pawl (5) to engage into a tooth gap

on the lock wheel (4)

When the park lock pawl (5) makes contact with a tooth in the park lock gear (4), a torsion spring (3) at the actuation shaft is tensioned When the vehicle moves, the tension of the torsion spring (3) causes the park lock pawl (5) to engage in the next tooth gap in the park lock gear (4)

DIAGNOSIS AND TESTING

Diagnosis By Symptom

General Equipment

Ford diagnostic equipment

Vehicle communication module (VCM)

 Go to Clutch Adaptive Learning

 Clutch  REFER to Clutch Unit

(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed

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Automatic Transaxle - 6DCT250, REMOVAL AND INSTALLATION)

 Input Shaft 2  REFER to Transmission

(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DISASSEMBLY)

 NVH in 3rd

and/or 4th

 Output shaft 2  REFER to Transmission

(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle -

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 No PARK /

Stuck in

PARK

 Selector lever cable

adjustment

 REFER to Selector Lever Cable Adjustment (307-05B Automatic

Transmission/Transaxle External Controls — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, GENERAL PROCEDURES)

 Park components

 REFER to Transmission 01B Automatic

(307-Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DISASSEMBLY)

 Go to Clutch Adaptive Learning

 Clutch  REFER to Clutch Unit

(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, REMOVAL AND INSTALLATION)

 NVH in

1st, 3rd,

 Clutch 1  REFER to Clutch Unit

(307-01B Automatic

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and/or 5th Transmission/Transaxle —

Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, REMOVAL AND INSTALLATION)

 NVH in 3rd

and/or 4th

 Output shaft 2  REFER to Transmission

 NVH in all

gears

 Differential  REFER to Transmission

(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle -

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adjustment

 REFER to Selector Lever Cable Adjustment (307-05B Automatic

Transmission/Transaxle External Controls — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, GENERAL PROCEDURES)

 Park components

 REFER to Transmission 01B Automatic

(307-Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DISASSEMBLY)

Diagnostic Parameters Identification (PID) Chart

NOTE: The following general PID list may be of use to the technician when exercising

output state control:

Accessing PIDs

1stBLCK_GR_JMP 1st Gear Is Blocked Due To Gear Jump Occurred

1stBLOCK_TMP 1st Gear Is Blocked Temporarily Protect Mode

2ndBLCK_GR_JMP 2nd Gear Is Blocked Due To Gear Jump Occurred

2ndBLOCK_TMP 2nd Gear Is Blocked Temporarily Protect Mode

3rdBLCK_GR_JMP 3rd Gear Is Blocked Due To Gear Jump Occurred

3rdBLOCK_TMP 3rd Gear Is Blocked Temporarily Protect Mode

4thBLCK_GR_JMP 4th Gear Is Blocked Due To Gear Jump Occurred

4thBLOCK_TMP 4th Gear Is Blocked Temporarily Protect Mode

CLTC_A_BLCK Clutch A Actuator Blocked (a)

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CLTC_A_CLOS_F Clutch A Reference Position Closed Failed

CLTC_A_CUR_MES Clutch A Actuator Current - Measured

CLTC_A_F_MANAG Clutch A Failure Management Status

CLTC_A_LOWCONF Clutch A Low Confidence In Sensed Position CLTC_A_MTR_DSD Clutch A Actuator Motor - Desired

CLTC_A_OPEN_F Clutch A Reference Position Open Direction Failed CLTC_A_POS_F Clutch Motor A - Position Sensor Fault

CLTC_A_SEQ_F Clutch Motor A - Phase Sequence Fault

CLTC_A_SLFDIAG Clutch A Self Diagnostic Procedure Status

CLTC_A_SLIPMES Clutch A Measured Slip

CLTC_A_SPRNG Clutch A Spring Cannot Fully Open Clutch

CLTC_B_BLCK Clutch B Actuator Blocked (b)

CLTC_B_CLOSE_F Clutch B Reference Position Closed Failed

CLTC_B_CUR_MES Clutch B Actuator Current - Measured

CLTC_B_F_MANAG Clutch B Failure Management Status

CLTC_B_LOWCONF Clutch B Low Confidence In Sensed Position CLTC_B_MTR_DSD Clutch B Actuator Motor - Desired

CLTC_B_OPEN_F Clutch B Reference Position Open Direction Failed CLTC_B_POS_F Clutch Motor B - Position Sensor Fault

CLTC_B_SEQ_F Clutch Motor B - Phase Sequence Fault

CLTC_B_SLFDIAG Clutch B Self Diagnostic Procedure Status

CLTC_B_SLIPMES Clutch B Measured Slip

CLTC_B_SPRNG Clutch B Spring Cannot Fully Open Clutch

CLTC_MTR_A_F Clutch Motor A - Phase Circuit Fault

CLTC_MTR_B_F Clutch Motor B - Phase Circuit Fault

CLUTCH_A_OPEN Clutch A Is Completely Open - Measured

CLUTCH_B_OPEN Clutch B Is Completely Open - Measured

FOOT_BRAKE Foot Brake - Foot brake state used by strategy

GEAR_ENGAGED Transmission Gear Engaged

GEAR_OSC Gear Command by Output State Control

GEARBX_SF_A_F Gearbox Error Status for Shift Fork A

GEARBX_SF_B_F Gearbox Error Status for Shift Fork B

ISS_A_PC_F Input Shaft Speed Sensor A - Power/Circuit Fault ISS_A_RAW Input Shaft Speed A - Raw

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ISS_B_PC_F Input Shaft Speed Sensor B - Power/Circuit Fault ISS_B_RAW Input Shaft Speed B - Raw

ISS_EFFECT_RPM Effective Input Shaft Speed

OSS_PC_F Output Shaft Speed Sensor - Power or Circuit Fault OSS_SRC Unfiltered Output Shaft Speed A

REVBLCK_GR_JMP Reverse Gear Is Blocked Due To Gear Jump Occurred REVBLOCK_TMP Reverse Is Blocked Temporarily Protect Mode

RLC Reverse Lamp Control

RLC_F Reverse Control Lamp Status

SF_A_CURR_MES Shift Fork A Actuator Current - Measured

SF_A_ENGAG_STA Shift Fork A Engagement Control Status

SF_A_GRRAT_MES Shift Fork A Gear Ratio - Measured

SF_A_POS_MES Shift Fork A Actuator Position - Measured

SF_A_POS_STAT Position Signal Status for Shift Fork A Actuator SF_A_POS_TARG Shift Fork A Actuator Position - Target

SF_A_ROTAT_MES Shift Fork A Rotational Position - Measured

SF_B_CURR_MES Shift Fork B Actuator Current - Measured

SF_B_ENGAG_STA Shift Fork B Engagement Control Status

SF_B_GRRAT_MES Shift Fork B Gear Ratio - Measured

SF_B_POS_MES Shift Fork B Actuator Position - Measured

SF_B_POS_STAT Position Signal Status for Shift Fork B Actuator SF_B_POS_TARG Shift Fork B Actuator Position - Target

SF_B_ROTAT_MES Shift Fork B Rotational Position - Measured

SHFRK_A_CAL_E1 Self Calibration Error - Shift Fork A Movement SHFRK_A_CAL_E2 Self Calibration Error - Shift Fork A Reference

SHFRK_B_CAL_E1 Self Calibration Error - Shift Fork B Movement SHFRK_B_CAL_E2 Self Calibration Error - Shift Fork B Reference

SHFRK_NO_CAL_0 Self Calibration Prevented - Brake Input Status

SHFRK_NO_CAL_1 Self Calibration Prevented - Clutch A is Not Open SHFRK_NO_CAL_2 Self Calibration Prevented - Clutch B is Not Open SHFRK_NO_CAL_3 Self Calibration Prevented - Output Shaft Speed SHFRK_NO_CAL_4 Self Calibration Prevented - Actuator Supply Voltage SHFTLCK_ALLW Transmission Range Shift Lock Output Allow

SHFTLCK_ALLW_F Transmission Range Shift Lock Output Allow Status SHIFT_A Shifting In Progress on Shift Fork A

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SHIFT_B Shifting In Progress on Shift Fork B

TCIL Transmission Control Indicator Light

TCS_DEPRES Transmission Control Switch Pressed

TCS_STATE Transmission Control Switch Requested State

TR_A_DC Transmission Range Sensor Input A Duty Cycle

TR_A_POS_MEAS Transmission Range Sensor A Position - Measured

TR_A_UR Transmission Range Sensor Input A Unreliable

TR_B_DC Transmission Range Sensor Input B Duty Cycle

TR_B_POS_MEAS Transmission Range Sensor B Position - Measured

TR_B_UR Transmission Range Sensor Input B Unreliable

TR_CORRECTED Transmission Range Sensor Position - Corrected

TR_CRANK Transmission Range Input Allowing Engine Start

TR_CRANK_F Park Neutral Starter Enable Output Fault Detected

TR_SUPPLY_F Transmission Range Supply Voltage Output Fault

TRAN_RAT Transmission Gear Ratio

Diagnostic Trouble Code Charts

General Equipment

Ford diagnostic equipment

Vehicle communication module (VCM)

Diagnostic Trouble Code (DTC) Chart

Disabled 3rd and 5th gears Only engage

in 1st gear at a stop

Neutral shift drum 1 after launch

REFER to Pinpoint Tests

- OSC Equipped Vehicle(307-01B Automatic Transmission/Transaxle

— Vehicles With: Speed Automatic Transaxle - 6DCT250, DIAGNOSIS AND TESTING) and GO to Pinpoint Test

6-C

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Disabled 2nd, 4th and 6th gears

Neutral shift drum 2

in forward range

Substitute ABS wheel speed, input shaft speed sensor 1

or input shaft speed sensor 2 for OSS

ce

Turn off transmission torque

up requests

See more specific DTC

If no other DTCs are set, clear code and re-test

See more specific DTC

Adjust Selector Lever Cable REFER to Selector Lever Cable Adjustment (307-05B Automatic Transmission/Transaxle External Controls — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, GENERAL PROCEDURES)

If concern still present, replace TR sensor P070

6

TR Sensor A

Circuit Range/

TR sensor A frequency out of

 Default to NEUTRAL

- OSC Equipped Vehicle

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Performance range (200-300

Hz) Code does not set for open, short to ground or short to power (duty cycle less than 2.0 or greater than 98.0 disables this code)

at low speed

 Crank disabled if fault present

at start-up

 Will turn on Malfunction Indicator Lamp (MIL)

(307-01B Automatic Transmission/Transaxle

at low speed

If concern still present, replace TR sensor P070

8

TR sensor A

Circuit High

TR sensor A duty cycle out of range high (below Low Max duty cycle)

at low speed

at start-up

 Will turn on

MIL

 Sets with P0706, P0707 or P0708

 Will turn on

MIL

Disabled 3rd and 5th gears Only engages

in 1st at a stop,

- OSC Equipped Vehicle(307-01B Automatic

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Neutral Shift Drum

1 after launch

Transmission/Transaxle

Detection of this fault is disabled if

a power supply (P06A6) or circuit fault (P0715) is present

in 1st at a stop, Neutral Shift Drum

1 after launch

in 1st at a stop, Neutral Shift Drum

1 after launch

 Disabled 3rd and 5th gears Only engages in 1st at a stop, Neutral Shift Drum 1 after launch

 Sets with P06A6, P0715, P0716 or P0717

 Will turn on Malfunction Indicator

6-C

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Detection of this fault is disabled if

 Substitute ABS wheel speed, input shaft speed sensor 1 or input shaft speed sensor

2 for OSS

 Will turn on

— Vehicles With: Speed Automatic Transaxle - 6DCT250, DIAGNOSIS AND TESTING)

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6-Malfunction Indicator Lamp (MIL)

and GO to Pinpoint Test

 Shift drum 2 mechanical fault

 Shift drum 2 motor fault

 Electrical faults that prevent shift drum 2 from rotating (open circuits cannot be detected during operation)

 Clutch 2 stuck on (if undetected may prevent shift drum 2 movement)

 2nd, 4th and 6th gears disabled

 REPAIR all speed sensor, clutch motor 2, and clutch 2 performance DTCs first

 REFER to Pinpoint Tests - OSC Equipped Vehicle (307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DIAGNOSIS AND TESTING) and GO to Pinpoint Test B

 INSPECT shift drum, shift fork, synchronizer and TCM Shift Motors for wear

or damage REPLACE as needed REFER

to Transmission(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DISASSEMBLY

 REPAIR all speed sensor, clutch motor 1,

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gear  Shift drum 1

motor fault

 3rd and 5th gears disabled

and clutch 1 performance DTCs first

 Electrical faults that prevent shift drum 2 from rotating

 REFER to Pinpoint Tests - OSC Equipped Vehicle (307-

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(open circuits cannot be detected during operation)

 REVERSE, 4th and 6th gears disabled

01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DIAGNOSIS AND TESTING) and GO to Pinpoint Test B

 Clutch 1

 REFER to Pinpoint Tests - OSC Equipped Vehicle (307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250,

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stuck on (if undetected may prevent shift drum 1 movement)

 1st and 5th gears disabled

DIAGNOSIS AND TESTING) and GO to Pinpoint Test B

 prevent shift drum 2 from rotating (open circuits cannot be detected during operation)

 REVERSE, 2nd and 6th gears

 INSPECT shift drum, shift fork,

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disabled synchronizer and

TCM Shift Motors for wear

 1st and 3rd gears disabled

to Transmission

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(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle - 6DCT250, DISASSEMBLY

 REVERSE, 2nd and 4th gears disabled

to Transmission(307-01B Automatic Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle -

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6DCT250, DISASSEMBLY

 Motor turns, but cannot synchronize and engage REVERSE gear

 Reverse gear

is disabled

INSPECT shift fork and synchronizer for wear or damage REPLACE as needed REFER to Transmission (307-01B Automatic Transmission/Transaxle

— Vehicles With: Speed Automatic Transaxle - 6DCT250, DISASSEMBLY) P073

6-F

Unable to Engage

Gear 1

Shift drum 1 is unable to engage 1st gear

 Motor turns, but cannot synchronize and engage 1st gear

 1st gear disabled

6-A

Unable to Engage

Gear 2

Shift drum 2 is unable to engage 2nd gear

 Motor turns, but cannot synchronize and engage 2nd gear

 2nd gear disabled

 For certain faults shift drum controls will not pass through a failed gear;

reverse, 4th and 6th gears may also be disabled

— Vehicles With: Speed Automatic Transaxle - 6DCT250, DISASSEMBLY)

 Motor turns, but cannot synchronize

INSPECT shift fork and synchronizer for wear or damage REPLACE as

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and engage 3rd gear

 3rd gear disabled

1st and 5th gears may also be disabled

needed REFER to Transmission (307-01B Automatic Transmission/Transaxle

 Motor turns, but cannot synchronize and engage 4th gear

 4th gear disabled

reverse, 2nd and 6th gears may also be disabled

 Motor turns, but cannot synchronize and engage 5th gear

6-E

Unable to Engage

Gear 6

Shift drum 2 is unable to engage

 Motor turns, but cannot

INSPECT shift fork and synchronizer for wear or

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6th gear synchronize

and engage 6th gear

damage REPLACE as needed REFER to Transmission (307-01B Automatic Transmission/Transaxle

— Vehicles With: Speed Automatic Transaxle - 6DCT250, DISASSEMBLY) P07A

1st, 3rd and 5th gears disabled

Check the clutch for wear or damage REFER

to Clutch Unit (307-01B Automatic Transmission/Transaxle

— Vehicles With: Speed Automatic Transaxle - 6DCT250, REMOVAL AND INSTALLATION) P07A

 Spring

 Blockage

 3rd and 5th gears disabled

off

Reverse, 2nd, 4th and 6th gears disabled

 Spring

 Blockage

 Reverse, 2nd, 4th and 6th gears disabled

— Vehicles With: Speed Automatic Transaxle - 6DCT250, REMOVAL AND

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6-INSTALLATION) P080

5

Clutch Position

Sensor A Circuit

Clutch motor 1 (ATIC) fault

Reverse, 2nd, 4th and 6th gears

- OSC Equipped Vehicle

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REFER to Charging System (414-00 Charging System - General Information, DIAGNOSIS AND TESTING) P090

1st 3rd and 5th gears disabled

6-A

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Will turn on MIL REFER to Pinpoint Tests

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