Powershift automatic transmission: device, principle of operation, reviews of car owners

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

The automotive industry does not stand still. Every year there are more and more new engines, boxes. Ford was no exception. So, a few years ago, he developed a robotic dual-clutch gearbox. She received the name Powershift. Automatic transmission from "Ford" has a special device and principle of operation, which differs from classic machines. Well, let's pay special attention to this box today.

Characteristic

So what is this transmission? Powershift automatic transmission is a robotic gearbox in which the gearshift function is automatically performed by the drive.

In fact, this is the same robotic box as the DSG, with a dual clutch. When creating this box, the manufacturer tried to embody all the advantages of mechanics and machine guns. Where is this transmission used? Now you can meet the Ford Focus 3 with Powershift automatic transmission, as well as the second generation Focuses. Sometimes such a transmission was installed on Volvo cars.

Automatic transmission devicePowershift

This transmission includes two final drive gears. They work in tandem with their own clutch. A feature of the Powershift automatic transmission for Ford is the presence of two input shafts. One is inside the other. So, the first one activates the reverse gear, as well as all the even-numbered stages of the box. The second is responsible for the inclusion of odd gears. This shaft is also called the central shaft.

It should be noted that the Powershift automatic transmission does not have a torque converter as such. Also, there are not a number of other elements familiar in classic automatic transmissions:

• Friction discs.
• Planetary gear.

The TCM block is provided as a control mechanism in the Ford Focus Powershift automatic transmission. This is the transmission control unit, which is located on the box body. His responsibilities include collecting all input pulses from sensors and processing information. Next, the block generates a control signal that is transmitted to the actuators. TCM also monitors the operation of all automatic transmission mechanisms in real time. The unit also controls the speed change. This can be done with DC electric motors. Special Hall sensors are built into them.

How does this box work?

The essence of the Powershift automatic transmission is as follows. While the car is moving in one gear, the second is already engaged (that is, pre-engaged). However, it has not been activated yet. And it is included in the work only throughelectromagnetic control, which uses a dry clutch disc. It is worth noting that switching gears in the Powershift automatic transmission occurs instantly, and even faster than a race car driver would do on the mechanics. This is the main advantage of the Powershift automatic transmission. Ford Focus with this gearbox accelerates faster than any other transmission (despite the fact that the engine will be the same).

Depending on the needs of the driver and the position of the accelerator pedal, one clutch can open and the second one immediately turns on. The automatic transmission mode itself is determined by the position of the selector in the cabin. The connection between it and the box is carried out using a cable.

About the clutch

As we noted earlier, this box does not have the usual wet clutch torque converter. It's "dry" here. Also, the clutch mechanism has automatic wear adjustment. Due to this, the desired stroke of the actuators is maintained. Also in the mechanism there are torsional vibration dampers. These are special damper springs built into the flywheel. The latter, by the way, is a two-mass one. Thanks to the dampers, vibrations and jerks are reduced. That is, the gear shifting is carried out not only quickly, but also gently. The clutch assembly itself includes the following elements:

• DC motors.
• Double release bearing.
• Electric lever type actuators.
• Clutch unit with dry driven discs.

Key Benefits

ThisThe box has several advantages. The first of these is the absence of a break in the flow of torque that goes from the engine to the wheels. This characteristic is achieved thanks to a dual-mass flywheel. The second plus is the acceleration dynamics. The automatic transmission loses a lot of time to switch from first to second gear when accelerating. Here, this operation takes place in a matter of moments. Thanks to this, maximum acceleration dynamics is realized. Also, with this box, the car consumes less fuel. If we take into account the usual six-speed box, then the savings will be about one and a half liters for every hundred kilometers.

Complaints and feedback from owners

But every box has a downside. The robotic automatic transmission "Powershift" is also imperfect and has a number of disadvantages. First of all, the owners complain about its unreliability. There were a lot of calls to the service even before the end of the warranty. So, on a run of 15-30 thousand kilometers, car owners faced such a problem as vibrations and jerks when switching gears, as well as when trying to move off. These vibrations did not go away until the fourth gear. This defect was explained by a failure in the software of the box and was “cured” by adaptation. What is its essence? Adaptation is an update of the box software and its “learning”. During the diagnostics, the masters identify all the causes of the malfunction and eliminate them. If defects were found, the official Ford dealer changed the clutch under warranty. So, many owners of Focuses had a new clutch installed at 20 thousand kilometers.

Nextthe problem that owners of a Focus 3 car with a Powershift automatic transmission face is the leakage of seals and seals. This is especially true for drive components. Over a short period of operation, oil begins to ooze from the seals. As a rule, this happens at a run of 30 thousand kilometers. A characteristic disease of these boxes is the leakage of the input shaft seals. Because of this, oil gets into the dry clutch. The result is disk slippage.

Another problem is the jamming of the clutch forks. Since there are two disks, there are several forks. And they jam at the same time. All this happens in about one run. Therefore, the robotic box is being repaired in the complex: the clutch, oil seals and forks are changing.

Also, the TCM module and electric actuators of the engine, which are responsible for clutch release and gear shifting, cause criticism. The box starts to glitch and kick when you try to move, as well as pick up speed on the car. This problem was observed in every second owner of the Ford Focus, which is equipped with a Powershift robotic box.

And perhaps the most serious drawback is the cost of all parts and repairs. So, a set of original clutch discs for a robotic box costs about 85 thousand rubles. Clutch forks - 67 thousand, and the control module costs about 49 thousand rubles. The most innocuous part is the input shaft seal. It costs 1300 rubles, excluding the cost of replacement work. As a result, to sort out a box at the service, you need to spend more than 200 thousandrubles. Therefore, many owners hastily sell such cars before the end of the warranty period. And in some cases, whole boxes are already bought at disassembly. By the way, the dealer himself was sometimes engaged in SKD replacement. Sometimes putting a different box was more profitable than sorting out the old one (which had traveled no more than 50 thousand kilometers).

About oil

Do I need an oil change in a Powershift automatic transmission? The manufacturer says the following about this. Automatic transmission "Powershift" is a maintenance-free box. The oil is filled for the entire period of operation. The fact that this box is made maintenance-free also confirms the lack of a dipstick, as is found in conventional automatic transmissions.

But what do experts say about this?

Skilled auto mechanics say that changing the oil in the Powershift "Focus-3" automatic transmission must be done without fail. The regulation is 100 thousand kilometers. At the same time, it must be reduced to 60-80 thousand if the box is used in difficult conditions. These are constant traffic jams, car operation in winter at temperatures below 20 degrees, slippage and a sporty driving style.

Eternal oil does not exist. Every year, additives are thrown away, and their properties are lost. As a result, the box will work intermittently, significant damage will occur.

Oil level

When operating a car, it is important to monitor the oil level not only in the engine, but also in the box. As we said earlier, there is no familiar probe in a robotic transmission. Buthow to check the oil in the automatic transmission "Ford Focus-3" Powershift? To do this, you need to gain access to the bottom. Next, unscrew the control hole in the box and look into it. If the level is low, there will be no oil in the hole. If the box works with its low level, various breakdowns are possible. The transmission is unstable. In some cases, adding oil helps. You need to pour it until it oozes out of this hole. This indicates that the oil level in the Powershift automatic transmission is at its maximum.

Signs of premature replacement

But not always adding fluid can solve the wear problem. So, first you need to take a small amount of the old to check. Signs that the oil is unsuitable for further use are:

• Characteristic smell of burning.
• The presence of chips or fine aluminum dust.
• Black or dark brown liquid.

Thus, topping up with new oil will no longer solve the problem. In this case, it is necessary to resort to its complete replacement in the Powershift automatic transmission with the Ford Focus-3.

What to pour into a robotic box?

There is little choice here. Experts recommend using the original Ford brand fluid. It has the following markings:

WSS-M2C200-D2

You can also use analogues from Motul and Liquid Moli. However, it is important that the product meets all tolerances. In terms of oil volume, a Powershift automatic transmission uses far less lubricant thanin hydrotransformers. Since there is no "wet" clutch, the total filling volume is only two liters. But it should be understood that with an independent oil change, only 1.8 liters can be filled. A small part of the old one will still be present in the box. You can completely get rid of it only in the case of a hardware replacement, which is possible only at a specialized service station.

Why is it so important to change the oil in a Powershift automatic transmission?

To answer this question, it is enough to consider the consequences of the box running on a fairly worn out lubricant. So, driving on this oil results in:

• Quick wear of the internal components of the box.
• Change in operating temperature.
• Corrosion.
• Education of bullying.
• Increased wear of sealing elements.
• Increase the load on the automatic transmission units, as the strength of the oil film decreases and some of the elements work "dry".

Therefore, in order not to face premature failure of the box, it is important to change the oil in it every 80 thousand. And if the liquid has darkened, then even earlier than this period. It is also recommended to check the oil level. If it has decreased, and the liquid itself is in an acceptable condition, topping up is allowed. Well, if the oil is dirty and with obvious signs of wear (which we listed earlier), then only a complete, hardware replacement is needed.

Summing up

So we figured out what isrobotic automatic transmission "Powershift". This box received very mixed reviews. Many drivers scold this box. And there are a number of reasons for that. Ford Focus is far from a premium car, and the cost of repairing a box is simply fabulous. And if the car is under warranty, you can still somehow put up with it. But it is better to refuse to buy such a car with a mileage of 150 thousand. The warranty does not apply to such machines, and the unfortunate owner himself will bear all the costs of repairing the box. In fairness, it should be said that there were fewer calls for the repair of the Powershift automatic transmission than the DSG, which were installed on Skoda and Volkswagen until 2013. Nevertheless, a robotic "Ford" box will be less reliable than a classic automatic. And for many, this is the deciding factor when buying. After all, it is better to put up with higher consumption and less dynamics, but get a high-quality and trouble-free box that will not require such money for repairs.