The Rise and Fall of Ford's Dual-Clutch Powershift Gearbox
Published Date: 11th Aug 2023
During the 2000s, Ford embarked on an ambitious journey to create a novel automatic gearbox known as the Powershift. This innovative dual-clutch transmission aimed to enhance fuel efficiency and performance. However, its introduction was marred by technical issues, leading to its eventual replacement with conventional automatic transmissions.
The Ingenious Dual-Clutch Design of Powershift
The Powershift hinged on a dual-clutch architecture, effectively integrating two manual transmissions within a single unit. This setup featured separate clutches for odd-numbered gears (1st, 3rd, 5th) and even-numbered gears (2nd, 4th, 6th). This unique arrangement facilitated seamless gear changes by preemptively engaging the next gear's clutch while disengaging the previous one. Consequently, the Powershift ensured uninterrupted transitions between gears, achieving smoother shifts than traditional torque converter automatics. Furthermore, this design eliminated the inherent power losses observed during gear changes in standard automatics, enhancing overall efficiency. The computer-controlled shifts were precisely timed to milliseconds and executed through mechatronic actuation.
Early Development and Launch
Ford partnered with Getrag and LuK to engineer the new Powershift in the mid-2000s. It was first introduced in 2010 on Ford's European models like the Focus and Fiesta. Ford gradually rolled it out globally on other vehicles over the next several years.
The first generation was called the 6DCT250. It used dry clutches engaged by electric motors and hydraulic actuators. In 2015, Ford introduced the upgraded 7DCT300 Powershift, which adopted wet clutches immersed in transmission fluid for better cooling capacity and friction management.
Early Marketing and Reviews
Ford positioned the Powershift as an amalgamation of manual gearbox efficiency and automatic convenience. Initial assessments lauded the transmission for its swift, seamless shifts and enhanced acceleration compared to conventional automatics. For instance, the Powershift-equipped Focus Titanium received praise for its brisk shifts and lively performance. Nonetheless, some early evaluations hinted at potential shortcomings. The dual-clutch system exhibited less smoothness when starting from a standstill. Reviews also noted instances where the transmission felt strained and unrefined during aggressive acceleration – early indicators of larger issues to come.
Problems Begin to Mount
Despite its theoretical promise, real-world usage of the Powershift unveiled reliability concerns. Owners reported problems like sudden power loss, excessive clutch shuddering, and premature wear, necessitating frequent repairs. The intricate electronics and hydraulics struggled to coordinate the dual-clutch system under diverse conditions flawlessly. Additional gripes included "jerky" gear shifts during stop-and-go driving and noticeable hesitation between gear changes due to prolonged clutch engagement. These issues collectively eroded the transmission's drivability and customer satisfaction.
Class Action Lawsuits and Fixes
By 2016, Ford was entangled in class action lawsuits in the US and Australia, alleging design and performance defects in the Powershift. Plaintiffs contended that the transmission was susceptible to "shuddering, slipping, bucking, jerking, hesitation while changing gears, premature internal wear, delays in downshifting and, in some cases, sudden or delayed acceleration." In response, Ford extended the Powershift's warranty and released several software updates to improve shift quality. However, these remedies failed to fully address the fundamental design flaws and hardware limitations, solidifying the Powershift's reputation for subpar reliability.
Global Phase Out
Following the conclusion of the Powershift lawsuits in 2018, Ford opted to phase out dual-clutch automatics globally. Across North America, Europe, and Australia, the Powershift was discontinued in favour of conventional torque converter automatics with six or more gears. These new transmissions showcased superior dependability in everyday driving scenarios.
Ford Models Featuring PowerShift Transmission:
Ford Fiesta - Since 2010, the Fiesta has featured the PowerShift dual-clutch transmission across various trims such as Zetec, Titanium, and ST-Line.- Ford Focus - Introduced in 2011, the Focus compact car offered the PowerShift option in higher trims like Titanium, ST-Line, and Active.
- Ford EcoSport - The subcompact EcoSport SUV paired PowerShift with the 1.0-litre EcoBoost engine in Titanium models.
- Ford Puma - The Puma subcompact crossover provided the PowerShift option with the 1.0 EcoBoost engine on Titanium and ST-Line trims.
- Ford Kuga - It was available with select engines; the Kuga compact SUV offered PowerShift on higher trim levels.
- Ford Mondeo - While the Mondeo has been discontinued, PowerShift was available in higher Mondeo trims like Titanium and Vignale when paired with specific engines.
- Ford S-Max - The S-Max multipurpose vehicle was equipped with PowerShift on specific trim levels and engine choices.
- Ford Galaxy - The large MPV from Ford presented PowerShift transmission with select engines on higher Titanium and Vignale trims.
The PowerShift dual-clutch automatic transmission was widely accessible across Ford's range, primarily on higher trim configurations and compatible engines. Its objective was to deliver smooth gear transitions and efficiency.
The Takeaway
In conclusion, the trajectory of the Ford Powershift serves as a cautionary tale about the intricate challenge of introducing cutting-edge transmission technology to a broader audience. While the dual-clutch Powershift held theoretical promise, its practical implementation fell short. Despite its innovation potential, the Powershift couldn't deliver the desired durability, drivability, and customer satisfaction. Ford's return to conventional automatics reaffirmed the continued merits of hydraulic torque converters until alternative technologies attained true perfection. The Powershift embodies both ambition and disappointment in Ford's quest for the future of transmission technology.
Lessons Learned
In response to the widespread issues encountered with the Powershift transmission, Ford demonstrated a commitment to acknowledging and addressing their shortcomings. The challenges faced by the Powershift prompted Ford to reevaluate its approach to introducing advanced transmission technology, emphasizing a renewed focus on quality, reliability, and customer satisfaction. This reflective stance reflects Ford's dedication to learning from past missteps and striving for continuous improvement. Notably, in the wake of Powershift's decline, Ford has introduced new technologies that have seamlessly integrated into the driving experiences of UK car owners. Examples include the incorporation of hybrid and electrified powertrains in models like the Ford Mustang Mach-E and the Ford Kuga Plug-In Hybrid, offering eco-conscious options for motorists seeking efficiency and reduced emissions. Additionally, Ford's deployment of advanced driver assistance systems, such as adaptive cruise control with lane-keeping assist, enhances safety and convenience on UK roads, showcasing the company's ability to successfully integrate innovative technology to benefit car drivers in the UK.
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