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lasse1955

Fix Durashift Gearbox Problem Easy.

137 posts in this topic

Hello Lasse

Please give me your adress, i will send you a present ! :wub:

Many-many thanks :)

I have made some videos for testing the actuators:

Actuator/Stellmotor-1, no problems:
http://lambertus.info/durashift/durashiftactuator2%20ok.mp4

Actuator/Stellmotor-2, with problems:
http://lambertus.info/durashift/durashiftactuator1%20fail.mp4

Actuator/Stellmotor-2, repair by Lasses Topic, now its good B)
http://lambertus.info/durashift/durashiftactuator2%20repariert.mp4

(when you have problems with the videos, there run in VLC-Player)

THX Holle

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Holle,

An excellent contribution! many thanks!

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Hello All,

I have had a '04 Fiesta LX 1.4 Durashit since August '13 and it has always been problematic.

It has all of the symptoms described in the original post (some slow gear changes and on a rare occasion the yellow cog of death...) and also the occasional clutch judder at pull off (happens when trying to pull away very slowly - like in slow traffic) as mentioned by someone earlier (this may require a further procedure :rolleyes:).

I have had the car looked at by independents and the Ford main stealer - Who quoted me £2500 to "maybe" fix it, and charged me £100 for the privilege!!

As the car has devalued so much I've now decided to try and fix the problem myself. :ermm:

I have some mechanical experience, service, brakes, timing belts, clutches, etc. With many vehicles from cinquecentos to transits, So in theory this should be a piece of p*ss. B) But I take nothing for granted!!!

I will take up the gauntlet of filming the procedure and I'll upload it to YouTube, *if I succeed*.

If not I will disappear quietly into the cyber darkness... :ph34r:

Wish me luck...

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Hi Graeme.

Hopefully you can fix it! I think the biggest issue is finding a video getting at the actuator in the car, and removing it so if you can achieve that, then its a good start to help anyone, plus the video's above of testing it, the combination should be a great help!

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Hello

The actuator from the video was my old actuator, ford have build a new actuator in my Fiesta at Feb. 2012 at 102.000km, now, 137.000km, since Dez. i have new problems, 2-3 Gang (?) it is hanging, etc..

Yesterday the Fiesta going to total error, no Display, no Motor-Start. At morning i have switched the new actuator, and now i verry happy ITS RUN, AND RUN, AND RUN, AND RUN, AND RUN :) :)

But i must reset the electronics, switch of the battery, turn on the lights, 3hours, and the Durashift going new learning; turn on the ignition (Zündung), but NOT THE MOTOR, the actuators runs forward and back, checking a lot off things, after any (verry long;) )minutes, all was ok.

at lasse, you are my hero !! :)

Now i have the other actuator, that have the same problem !

Greats, Holle

sorry for my bad english, in moment im verry happy-nervoesly ;)

when anybody have that durashift-problem at my location (Germany/ Steinhuder Meer), come to me, we make it together (not for money, i will give back, that i have becomes here)

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Glad to see its behaving for you! :)

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Hello

Last days i have a idea to repair the actuator without removing it, and without open the plastik-tube. it ist verry easy.

The Durashift repair tool: :D

durashift%20repair%20tool.JPG

You must only remove actuator-motor-1, not the complettly actuator. Mark the actuator shaft position and dont turn the motor after removing.

Pull out the actuator-shaft, and use the Durashift-repair-tool, turn it carefull, and then clean the plastik-tube, at last make new oil in it.

Durashift%20repair%20tool%20at%20work.JP

at last, build everything together, and have fun B)

best regards, Holger

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Nice find their Holger,

Any linkls to where these tools can be bought?

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Hi Jeebowhite

I think, a "Durashift Repair Tool" have any hobbyist at home.
It is a old wooden spoon (perfect is a wooden-shaft with ca.14mm diameter), and fine sandpaper glued at the ends.

greats Holger

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I am having a similar problem...

My 04 transit will start everytime, but does not engage a gear, 1 or reverse. After idling for a while, it will finally shift into 1 or R, but when I depress the accelerator, it chugs/shudders and dies...as if it is in a high gear or as if a learning driver improperly operates the clutch. Once it finally decides to cooperate, there are no issues traveling, but downshifting (at times) is moderately rough.

After reading this and some other forums, I crawled under the engine today and noticed a fair bit of oil leaking near the transmission housing.

The AUTO light has been blinking since we bought it, but never had an issue until recently.

Any thoughts would be greatly appreciated.

Cheers.

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Thanks for posting this, it has been very helpfull in tracking down the fault in my Durashift fiesta, the ECU/clutch actiator was faulty so have removed it and had it repaired, any one know the correct procedure for bleeding the actuator and associated pipework have had a go using a pressurised system connected to the fluid reservoir and bled the fluid at the gearbox, got some air out but not sure I have it all as the car will not go into reverse ( gears are grating as if the clutch is not fully depressed) the car has the front wheels on ramps so dont want to try forward.

Regards Stuart

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Thanks Dan, tried in forward, could hear actuators working but would not go into gear then lost LCD gear indicator, had to unplug the ecu to get the lights back on and the car to start.

Regards Stuart

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A happy conclusion to the durashift nightmare, had another go at bleeding the ecu/clutch actuator this afternoon removed battery etc for easy access to the bleed nippple and used a 50ml plastic syringe (removed 3 syringes of fluid out of the reservoir to make room) and some 6mm rubber petrol pipe, and forced the fluid in through the bleed nipple I could hear the air being moved round the system, when the syring was empty I shut the bleed valve untill another full syring was attached and opened up and emptied the syringe, did it one more time put averything back together started the car all lights came on then went out as they should tried into forward went into 1st no problem, tried reverse, no probs so backed off the ramps.

Got the wife to test drive it as she uses it mostly, says its OK.

No thanks to Ford who wanted to charge me £1760 parts with no guarantee that it would work and charging me £80 to put it on the computer and not be able to identify the problem.

Thanks to www.ecu-testing.com who repaired my ECU/clutch actuator in a week and S&D transmissions Doncaster identifying the problem.

Juney00 likes this

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Hi,

Followed steps as instructed and hey presto it worked. Absolutely brilliant. I have no mechanical skills at all and managed to do this. I have a neighbour across the road this happened to and cost him £2000 from ford to have repaired. Mine cost price of lithium grease and an angled bit wrench (£15).

Remove battery holder first as it is much easier to get to everything.

Thanks

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Hi, I have a UK Ford Fusion, 1.4 Durashift, 2003 model. Initially the car stalled when decelerating from 4th gear. The car displayed 1 in the gear selector display and wouldn't start. However, we recovered it (so must have been in neutral) and I took out the Durashift gear actuators and cleaned them as per forum posts (thanks lasse1955).

The actuator assembly cleaned up OK and seems in quite a reasonable state as is the connected wiring harness (checked for cut wires and corrosion). Put the actuator back together and fitted but still no joy. The gear display is blank and I notice one of the actuators is constantly moving back and forwards (have left for 15 mins in case it was resetting) with the ignition on.

I took the car to a local garage and they advised received code: P0810 “clutch position error” from the Transmission Control Unit (TCU). The clutch was replaced (£600) and the car seemed to run fine yesterday… Although it seemed to be engaging the clutch too rapidly when cold as it stalled when moving off, possibly clutch bedding in... However I it tried today and getting exactly the same problem as before.

I believe the problem is likely to be the clutch actuator. Does anyone know of an exploded diagram of the unit as I’d like to inspect it, initially without disconnecting the hydraulics if possible... Or any other thoughts on what I could try as the bill for repair will soon exceed the value of the car. Many thanks.

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Hi!
Firstly, big thanks for the walkthrough.
I am in the process of trying this now, i just have a couple of questions that maybe you or someone else who's tried this could help me with -

I can have found and can remove all 4 of the bolts mounting the automator, as well as the two motor power cables. The only thing I wanted to be sure of before continuing, was removal of the bolt in the image below. It appears I would have to remove it before the whole assembly could be removed, but its fused on there and getting it off is going to be a pain. I'm worried about stripping it.

Does it have to be removed to get the automator off or will it slide off anyway?

Thanks for any help!! complete novice here.

post-59472-0-26099000-1414172622_thumb.j

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Evening Luke, if you move the rubber boot round the connection and have a look it is possible to disconnect this when the other 4 bolts have been removed the bolt that is seized just clamps the connection to the shaft. you need to move it about a bit to get it to disconnect but it goes back into position easier than it comes out.

Good luck.

Stuart

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Hi Luke, I didn't remove this bolt, once I pulled back the rubber cover the fitting popped out when I pulled the actuator away. The other thing I did was disconnect the ball joint (the fitting is black plastic in your photo). I did this by getting a screwdriver and levering it off. It snapped back on after refitting by using a pair of snipe nosed pliers. Another tip that made removal a lot easier was to remove the headlight, just 3 screws and unplug the connector, and the large pipe to the air filter. Hope that helps.

Quick update on my post of the 4th October... The Fusion is still in the garage, after contacting Ford / Transmission specialists, it appears the clutch actuator is likely to be at fault. The car is currently waiting for the actuator to be returned after being sent away to be reconditioned. I will post again if this finally resolves the fault.

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Hey, that's just what I was hoping someone would say! great, thanks. I will report back with photos for other peoples benefit :)

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Last update from me. Clutch Acctuator was reconditioned by a specialist the garage engaged (£170.00), it had worn motor bushes and a lose connection. Car has now been working fine for a month so that was the problem. I'm not surprised as it's used for the school run and lots of short journeys, this would mean the actuator has had to work hard during it's lifetime.

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Fantastic news, so what was the total cost in money and time?

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It turns out that the actuator rod wasn't likely to be my particular problem. It moved quite freely for me once removed from the car.

Although taking it apart gave me a chance to grease all the moving parts and check the motors (using the 12v from the battery). Maybe my problem was stiffness somewhere else in the actuator, much of it was rusty despite the plastic cover, so it may not have been a waste of time. If I continue to have problems i'll have a look at getting the clutch actuator serviced. (I understand this isn't an easy job?)

Anyone able to recommend someone in east london (im in E17) who wont rip me off for this?!

Further, does anyone know which exact transmission fluid I would need to change the fluid in this car, or where I can get it? The manual says to change it every 40k and i've done 90 without it being changed. Couldn't hurt and I understand its not very hard to do. Its manual transmission fluid as opposed to auto, right?

I've included some images I took during disassembly. I thought maybe they could help someone else with the same task. I obviously didn't need to bore out/sand the bushing at all, since the rod wasn't stuck and moved freely, so I just lightly greased it and reassembled.

In hindsight, this whole process could be done in less than an hour, although not having done it before, it took me about 3!

Thanks guys

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post-59472-0-43152600-1417014641_thumb.j

post-59472-0-81833800-1417014643_thumb.j

post-59472-0-14985700-1417014646_thumb.j

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Thank you my durashift work jet as new. I hope for a long time. :)

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