Clutch Shudder on Light Acceleration – Transmission Fluid Leaking from Clutch Housing – 2012-2016 Ford Focus & 2011-2015 Ford Fiesta

TSB 16-0109

DPS6 – AUTOMATIC TRANSMISSION – EXCESSIVE TRANSMISSION CLUTCH SHUDDER AND/OR TRANSMISSION FLUID LEAK

 

FORD:

2011-2015 Fiesta 2012-2016 Focus

 

This article supersedes TSB 15-0120 to update the vehicle model years, Service Procedure and Part List.

 

ISSUE:

Some 2011-2015 Fiesta vehicles built on or before 10/15/2014 and 2012-2016 Focus vehicles equipped with a DPS6 automatic transmission may exhibit excessive transmission clutch shudder on light acceleration. Some vehicles may or may not exhibit transmission fluid leaking from the clutch housing.

 

ACTION:

Follow the Service Procedure steps to correct the condition.

 

SERVICE PROCEDURE

Confirm that FSA 15B22 has been completed, if it is open in OASIS; perform the action to update the PCM/TCM prior to the action in this bulletin.

Refer to Workshop Manual (WSM), Section 307-01 for 2012-2016 Focus and 2014-2015 Fiesta. For 2011-2013 Fiesta refer to WSM, Section 307-11.

When referred to the WSM all steps listed in the WSM must be performed.

NOTE: PERFORMING THE SERVICE ROUTINES WILL CLEAR ADAPTIVE STRATEGY. FAILURE TO PERFORM ALL STEPS OF THE IDS ROUTINES MAY RESULT IN ERRATIC SHIFTS AND DRIVEABILITY CONCERNS.

1. Using IDS follow the WSM Diagnosis and Testing, Diagnosis by Symptom, Pinpoint Test A (All Focus and 2014-15 Fiesta) or Pinpoint Test N (2011-2013 Fiesta) – Clutch Shudder on Acceleration to diagnose shudder.
   1. Save and upload IDS Datalogger Session Data.
   2. For clutch replacement retrieve repair validation code (RVC).
   3. New vehicles with less than 1600 km (1000 miles) have not fully completed the clutch friction green clutch break-in period that is required before attempting to replace the clutch or hardware.
   4. Vehicles built on 6/6/2013 or later have the improved transmission input shaft seals that are unlikely to experience leaks and should only be replaced if leaking.
2. If the clutch is replaced, use IDS to reprogram the PCM/TCM to the latest calibration using IDS release 101.04 or higher. Make sure you are connected to the internet when entering module programming to obtain the latest updates. Calibration files may also be obtained at www.motorcraftservice.com.
   1. IDS software updates have been made to streamline the process and improve DPS6 Shudder diagnostics and reprogramming.
   2. Adjust the vehicle clock as required, it may have lost time during the reprogramming process.

Transmission differential seal plugs are now released and should be installed during transmission removal and while performing bench repairs to reduce/eliminate the loss of transmission fluid.

 

EV6Z-7052-C	Focus Seal Kit – (Figure 1) Required For All Clutch And Seal Repairs
EV6Z-7052-D	Fiesta Seal Kit – (Figure 1) Required For All Clutch And Seal Repairs
FA6Z-7B546-A	Dual Clutch Assembly Kit -Fiesta Built On Or After 1/13/2011
FA6Z-7B546-B	Dual Clutch Assembly Kit – Fiesta Built On Or Before 1/12/2011
F1FZ-7B546-B	Dual Clutch Assembly Kit – Focus
AE8Z-7007-A	Engine-to-Transaxle Separator Plate – 1.6L
XT-11-QDC	Motorcraft Dual Clutch Transmission Fluid
PM-4-A	Motorcraft Metal Brake Parts Cleaner
XL-2	Motorcraft High Temperature Nickel Anti-Seize Lubricant
F1FZ-7H183-A	Differential Seal Plug (2-req, can be used for multiple repairs)
BE8Z-6731-AB	Motorcraft Oil Filter FL-910S
XO-5W20-QSP	Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (1-quart)
1S7Z-6840-AA	Oil Filter Adapter Gasket – Focus
BE8Z-6L621-A	Oil Cooler Assembly Seal-Fiesta (As Needed)

 

OPERATION	DESCRIPTION	TIME
160109A	2012-2016 Focus/2011-2015 Fiesta DPS6: Perform Pinpoint Test Per WSM Procedure, Release The Vehicle, Within Expected Limits (Do Not Use With Any Other Labor Operations)	0.6 Hr.
160109B	2012-2016 Focus/2011-2015 Fiesta DPS6: Perform Pinpoint Test Per WSM Procedure, Outside Of Expected Limits Retrieve RVC Code, Requires RVC Code (Do Not Use With Any Other Labor Operation Except C Or D)	0.6 Hr.
160109C	2011-2015 Fiesta DPS6: Replace Clutch, Includes Reprogram The PCM/TCM, TCM Adaptive Learning And Post Road Test, Requires RVC Code (Do Not Use With Any Other Labor Operation Except B)	4.7 Hrs.
160109C	2012-2016 Focus DPS6: Replace Clutch, Includes Reprogram The PCM/TCM, TCM Adaptive Learning And Post Road Test, Requires RVC Code (Do Not Use With Any Other Labor Operation Except B)	5.2 Hrs.
160109D	2011-2015 Fiesta DPS6: Replace Both Inner Input Shaft Seals And Clutch, Includes Reprogram The PCM/TCM, TCM Adaptive Learning And Post Road Test, Requires RVC Code (Do Not Use With Any Other Labor Operation Except B)	5.1 Hrs.
160109D	2012-2016 Focus DPS6: Replace Both Inner Input Shaft Seals And Clutch, Includes Reprogram The PCM/TCM, TCM Adaptive Learning And Post Road Test, Requires RVC Code (Do Not Use With Any Other Labor Operation Except B)	5.7 Hrs.

 

WARRANTY STATUS

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

 

DEALER CODING

BASIC PART NO.	CONDITION CODE
7B546	42

 

Figure 1 – 16-0109

 

 

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Service Information & Reprogramming

Software necessary to program electronic modules to the latest calibration level, perform module initialization (PATS), and set Programmable Parameters on Ford, Lincoln and Mercury vehicles.

Ford Module Programming (FMP) is a software application that allows subscribers to program electronic modules on Ford, Lincoln and Mercury vehicles. It can be used for:

• Reprogramming emission-related (OBDII) modules on some vehicles manufactured in 1995 and all vehicles manufactured from 1996 to the present
• Reprogramming or reconfiguring non-emission-related modules on many vehicles (UBP and MS-CAN not supported)

In addition, module initialization (PATS) functions such as Keycode Erase/Reprogram and PCM Parameter Reset can be done using this application.

J2534 Device using Ford Module Programming (FMP) can Reprogram and Configure most Modules.

Latest Calibration Information

Module Build Data (As-Built)
Use VIN to obtain As-Built data

www.motorcraftservice.com