Mk2 Kuga Powershift (title edited)

Burnerman said:
Just wondering why the thing goes for a good few miles without problems, and then reverts to its old tricks.....I mean, it shouldn’t be temperature related and it hasn’t done enough work to get contaminated since your last investigation therefore the solenoids should still be sweet.
Just sticking new clutches in shouldnt make any difference.
You would think that there would be specialist firms able to cope with these things now - didnt they come about in 2003 or something?
Do the gearbox and metchatronic use the same lube?
John :)
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The oil bathes the clutches, lubes the gears/ bearings, runs though the mechatronic unit and solenoids.

Could be all sorts of microscopic metalic debris that has passed through the filter (bypass valve) over the years and clogged the clutch solenoid?.

Apparently they can't repair 50% of the clutch solenoids so wether it's contamination or they just wear out who knows?, the clutch solenoids will be working nigh on continuously all the time the car is in "gear" so first in the line to fail.

Seen the code "P0766" come up many times in searches, it's the "odd" clutch responsible for 1st and reverse (plus 3rd and 5th) so more used than the even clutch..
 
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Oh my word Keithmac! Hats-off to you for that level of skill, hard work and sheer bloody-mindedness! I'd never have the bottle to take on a job like that and I really feel your anguish!
 
+100!!
Surely the answer to these transmissions has to be a very high spec lube, shortish oil change intervals and intensive filtering......even wet clutches let go some debris.
I wonder if there are any magnets within the gearbox, as per slush transmissions.
John :)
 
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There's 3 magnets in the gearbox (2 on the internal filter and one on the vertical "sump".

The car is built around the gearbox, sends torque request etc to the engine ECU, would be a bit of an undertaking to fit a manual. The Intelligent AWD is also linked to the 'box (all through canbus).
 
Well good news is the car is going well, bad news is I can't trust it to do a long tow with our caravan really (why we bought it..).

I found a few small pieces of plastic/ nylon, the size of a large grain of sand or better the salt you put in a salt grinder.

So looking into this they use plastic/ nylon around the clutch damper springs!.

Basically every time you set off, the engine pushes the outer of the clutch basket which then pushes the springs (via plastic spacers!).

So all the load of setting off with a full car and 2100kg full tow on the back goes through plastic spacers/ guides..

At this point I've given up, either I have to take the gearbox apart and machine suitable replacements for the spring guides (no chance plastic/ nylon is going back in!) or get shut and lose probably 9k over 2.5 years use.

I've been in talks with the head Ford UK's office but they are being awkward.

Genuinely think this gearbox is "not fit for purpose".

How far do you go though?, shocking design all round imho..
 
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We had a Mondeo Ghia x 16 years ago that the auto box failed on one week out of warranty. The Ford dealer charged us £58 to tell us the box had gone and ford were not interested as it was out of warranty. We had it fixed by a company in Essex at a cost £1174. They told us the failure was due to the cheap circlips that Ford use in UK models and they put American circlips in. I will never buy another Ford.
 
Wow! I'm kind of watching this from between my fingers held across my eyes like a horror film! Part of me is willing you to machine the bits and "beat Ford's engineers" but I know I'd probably have chucked the towel in by now!
 
Getrag make the gearbox for Ford.

Unless by some magic Ford come up with anything it'll be the last Ford I buy and the last car that uses Getrag!.
 
Does it have a DMF? I'm wondering if that's a bit worn and there's some weird torsional oscillation being set up that is mashing those plastic spacers? (Or maybe they've just gone brittle after being immersed in the gear oil for a few years)?
 
No DMF, those springs de-couple the engine from the gearbox.

Like a DMF but not as stout!.
 
I'm just trying to decide what those plastic retainers actually do, how much stress they are under and why are they failing so dramatically?
For sure, the filtering will have to be spot on to cope with that, obviously magnets aren't any use here.
Have you got the thing in bits again, or is the clutch pic an older one?
John :)
 
Burnerman said:
I'm just trying to decide what those plastic retainers actually do, how much stress they are under and why are they failing so dramatically?
For sure, the filtering will have to be spot on to cope with that, obviously magnets aren't any use here.
Have you got the thing in bits again, or is the clutch pic an older one?
John :)
Click to expand...

This is from Macktrans, but the debris from mine is identical.
 
This was our first outing with our new outfit. My wife bought the caravan and I bought the tow car.

I'm sure everyone understands "dad sorts it all out". That's where I've been most of this year.

Took my B+E driving test as well which was two days of getting bolxcked plus a lovely 1.5 hr towing exam at the end.


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