Mk2 Kuga Powershift (title edited)

[norseman]

I think there's an element of luck when it comes to slush-boxes. I've read, from more than one source, than the auto-box (Jatco I believe) in our 06 Mondeo 2.0ltr. petrol is on borrowed time after 80k, but the car has now covered 167k. There are no records (from PO's) of the 'box ever being touched & none during our 81k ownership period.

 

[Keithmac]

Well the faults come back unfortunately, been quoted £2800+vat for a rebuild..

So my weekend off will involve getting covered in gearbox oil it seems..

Made a circuit so I can pulse the solenoids in a tub full of cleaner while I strip the valve body down and clean/ look for anything obvious.

67000 miles and the car is undrivable now, shocking really!.

****ed off doesn't sum it up but I've just got to get my head down and get on with it as we haven't got the money unfortunately.

Spent £15,000 pounds 2 years ago so I didn't have to faff about fixing the family car and been bitten in the ass..

Was never a fan of PCP but in hindsight I would have been far better off with a new one that I'll never own at this rate!.

 

[Burnerman]

Seriously bad crack Keith and I reckon if anyone can sort it you can.
Can you do some pics for us?
I must agree with your PCP comment, it's the only way I'd buy a dsg vehicle and I don't do PCPs!
Be lucky
John

 

[Keithmac]

Seriously bad crack Keith and I reckon if anyone can sort it you can.
Can you do some pics for us?
I must agree with your PCP comment, it's the only way I'd buy a dsg vehicle and I don't do PCPs!
Be lucky
John

Yep I'll take some picture John .

I suppose if rebuilding motorcycle engines as part of my job goes it should be fairly straight forward..

Wouldn't mind but I've been turning guvvie jobs down to have some time off the spanners but can't get away from them it seems!.

I have FORscan program up and running so can do Gear Shift Fork Position and Clutch Point learn after the job.

£150 an oil change as well, just worked out I've chucked nearly £600 in gearbox oil at it since I've owned it..

I was really low at work this morning but **** happens and you just have to make the most of it. Wife children and dog are in good health and a roof over our heads so that's most important things sorted.

 

[norseman]

Feel free to correct me, but my understanding of these transmissions is that they are 'self changing gears' rather than auto's in the true sense of the word, at least compared to the old school units that began to be fitted to large UK cars as far back as the mid 'fifties ie Borg Warner DG & later BW 35. I've had various of these early 'boxes in cars & only ever had one fail. The Jatco (?) in our Mondeo has now done 170k & I've a ZF in my old Range Rover that's 31 years old.

 

[Burnerman]

Whereas the old slush boxes used a torque converter as a clutch if you like, the dsgs are actually in gear and ready to spin once the internal clutches are operated so there is no similarity between the two.
I do feel the sucess of the dsg system will be determined by the correct oil and perfect filtering but it seems we have a while to go yet.
John

 

[norseman]

I do feel the sucess of the dsg system will be determined by the correct oil and perfect filtering but it seems we have a while to go yet.
John

Thanks for the clarification, also a considerable difference in replacement costs over the old 'boxes I suspect.
'Oh how I love technology (not) but then I'm an old fart

 

[Burnerman]

For sure I quite like the idea of dsg but too many people I know have had bother which scares me.
I think I'd go down the PCP route if I took the plunge!
John

 

[Keithmac]

Managed to get all jobs done at work this morning so took pm as a holiday.

Dug into the car, I needed approx 10 inches of extra clearance to get the Mecatronic unit out (easy peasy..).

Be all and end all due to how they've designed the MK2 Kuga I've had to remove the entire front of the car!.

A couple of in progress pics but I was racing against the light at the end.

Will be stripping the valve body down tomorrow.

 

[Burnerman]

Eagerly awaiting the next instalment!
John

 

[Keithmac]

It's cost me 5 hours, on the Mk1 you can remove the fan assy for clearance.

On the MK2 the slam panel is in the way so it's all off, bumper/ lights/ wiring/ crashbar and part of the subframe..

Will take some pictures tomorrow.

Must admit the wiring loom is very well secured and built, see quite a few loom faults at work due to vibration and chafing but Ford have done a good job there.

 

[mointainwalker]

" guvvie jobs "

So long since I heard that expression - late 70's at Hepworth and Grandage in Bradford IIRC.

 

[Burnerman]

Doesn't everyone do the occasional guvvy?
John

 

[Keithmac]

Here you go John, I decided the wet clutches couldn't possibly be worn out at 67k so decided to try a Mecatronic rebuild first.

Two full days of graft to get unit out (basically front of the car had to come off first), stripped / cleaned / inspect and test all solenoids (9) and actuating pistons etc.

Took my time stripping it and photographing everything as it's extremely complex.

I soaked the solenoids in Seafoam while I serviced the valve body.

I was a bit annoyed not to find anything obvious, all the internals look like new still.

Was a bit weary before test drive but she's smooth as silk!, best it's ever driven.

Done 10 miles tonight and need to put some more on tomorrow but very hopefully indeed!.

 

[Burnerman]

Ye gods
Thanks ever so for the update, makes for incredible, if not terrifying, viewing!
Everything looks absolutely perfect, no wear or debris visible......on occasions when I've been into things as deep as this (but never so complex) and not found anything I tend to find the original fault is somewhere else after all - if indeed I can find it!
Fingers tightly crossed for the outcome, but if the fault returns, where do you go from here?
How long are the clutches expected to last, do you know?
Thanks again
John