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Fix Durashift Problem 2

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#1 wase16ll


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Posted 22 March 2013 - 12:49 AM

this is a write up of a common problem with fiesta 1.4 durashift problems.
well worth checking especially if you follow the excellent guide posted elsewhere for the actuator guide bush.

this is a seperate problem that gives very similar symptoms to the actuator bush, such as
non start
various dash display irregularities
rough gear changes
no gears/changes

ideally, if your fiesta is suffering from any of the above symptoms then you need to look at both the gear change actuator bush/shaft, explained elsewhere on this forium....AND the wiring loom which i shall try to go through now.

i have come accross the following problem on 4 different fiesta durashifts, plus i have spoken with a very well respected diagnostic tech for info from his personal experience...this is the interesting part
along with the 4 fiestas ive come accross with this problem, he informed me that he has dealt with far, far more and found exactly the same. guess what, he has yet to come across a durashift that needed actuator motors or the control unit.... I find that suprising when ford themselves seem to diagnose ecu/actuators more often than not..

the following is a very inexpensive, but time consuming operation.
so i shall begin :)

as most will know, the positioning of the control module and actuators leaves them very vulnerable to all the rain/salt/grit etc of day to day driving, there lies the problem.
the control module has 2 main plug connections, the lower plug carries the wiring from the main engine loom, the upper plug carries the wires to the gear actuators.
first, disconnect the battery. [dont forget to check you have radio code] i find it far easier to remove the battery and battery tray when repairing these, especially if removing the actuator to check/repair the guide and bushing at the same time..just gives more room to play with.
disconnect the 2 plugs from the control module
to make life easier for yourself, disconnect the cooling fan, reverse light switch and actuator connectors too...remove the clips that secure the looms to the gearbox and cooling fan housing [just carefully lever them away]
this gives enough movement to be able to lift the loom and allow you to work from above rather than crawling around underneath.
you now need to carefully remove all the insulation surrounding this section of the loom, a sharp stanley blade is useful for this, but be careful you dont damage the wiring within.
as you strip the loom insulation, it will become apparent that the plugs to the actuators/ upper control unit plug is a seperate loom from the main engine bay loom...its this particular section of loom that is often found damaged/corroded

once insulation is completely removed from this section, carefully inspect all the wires for any signs of corrosion [wire insulation is slightly bulged], cuts in insulation and complete breakages..this is very common, so take your time and check carefully, but more often than not, damage is obvious.
at this point i should add that because this loom is relatively short and seperate from the main loom, it may well be available to buy from Ford, as yet i havent asked as they are quite straight forward to repair for any reasonably confident DIYer.
in order to repair this damage, cut the wire, you now need to peel back the wire insulation untill you find good, clean copper on both sides of the cut, this is important, corrosion needs to be removed, so if the copper is looking black, then keep cutting back...this corrosion can often go right back to close to actuator connectors, try not to cut back too closely to this plug, often find the wire is still not shiny new copper, but can be cleaned with gentle rubbing with emery cloth or similar.
you will now need to solder a jump lead between the cuts, this is far more permanent than using electrical connectors to rejoin the wires, but its your choice. i recommend soldering though...making sure you use same size wire for jump lead
take your time to get it right, when done, you now need to reinsulate the loom, i find it best to use insulation tape to cover the whole loom, then refit the loom casing and cover this too with insulation tape.
go back to the main loom that leads to the lower control unit plug, remove the outer loom insulation, you only need to go back about 12"-18".....once wires are exposed, once again check carefully for any damage on the wires, repeat the repair and reinsulation process...
reassemble the looms, battery etc.
that is it, your done...combine the above with the checking/repair of the gear selector shaft/bush and you will have cured 99% of problems with the durashift...

hope you find this useful and informative, sorry about the spelling etc, but been a hard day ;] and guess what, one of the jobs today, was repairing the loom of a durashift :) hence the write up.

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#2 wase16ll


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Posted 27 March 2013 - 12:28 AM

just a quick update/correction
gearbox actuators ARE known to fail, i misinterpreted what the techie told me...came to light when working on yet another non-start durashift..been getting a run of these last couple of months.
once again, found corrosion within the loom as explained [hopefully ;) ] above.
put it all back together, got it running, took for a spin, started off fine, but couple miles down the road it struggled to change gear, ending getting stuck in first.
managed to get it back, but knew that car was stuck in gear, so soon as engine cut out, knew i was back to non start.
double checked everything was still in place then plugged machine back in....sure enough, code for clutch position sensor was logged again, went into live dats and found ecu thinking car is actually in fourth gear, whilst selector is in neutral...hence the loss of gear changes and return of non start.

rang to pick the techies brain again, between us came to conclusion its the actuators, something he has come across a few times, it was the control unit and gear selector unit that he and a trained ford diag tech had never yet been able to fault or change,
real shame as this means i'll probably have to sub the work out as i dont posess the necesary software to programme the new actuators in.....hopefully a few calls tomorrow will turn up trumps.
so anyway, apologies for the misleading info in above post, but just be wary if anyone tries to tell you the ecu or gear selector are knackered...chances are, they're wrong

#3 stanski



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Posted 31 July 2013 - 03:52 PM

First - Thanks for super writeup of the electrical loom check. 


This problem for me only started on Monday when wife was trying to get to work. After not using the car for a few weeks she had forgotten to put foot on brake pedal to initiate start up.  Have had the car 3 months. It is a Fiesta 1.4 - 55 reg, 56k miles.


Symptoms were no gear indication in display, then loss of display and then after me checking connections the transmission warning message with red led.  Tried starting with brake depressed, display reappeared with no gear indication then dissappeared when key turned to initiate starting.


INITIAL thought - Possible low battery as car had not been used, so jumped it.  Car started - all looked good so drove away to charge battery, managed two up and three down gear changes then set it to auto to continue.  After 1/2 mile sudden loss of drive and no gear indication in display - engine still running.


Display would only show a gear, 1 or R whenever brake pedal was depressed, also auto option could be removed or selected but could not engage gear.  Parked car on side of road and recovered it today.



Read about the electrical and actuator solutions, chose to go the electrical route for initial ease.


I dicided not to follow the suggested practice of removing the battery, only removed the air intake and found that there was adequate room to acess the loom and remove all the tape & protective plastic conduit.  Started at 2pm, taking it slowly and with a sensible approach had the loom seperated within 40 mins.


Found no electrical wiring problem by inspection so next is to investigate the Actuators.


I did stupidly fall into a trap of trying to put the wrong plug back in the control unit and found stupidly it would not fasten.  Why I did it was because of the quantity of major connectors showing - fooled as not all pins are used.


So am about to tackle the actuators but will have to wait as about to go on holiday tomorrow.  Had a quick visual check and need to confirm best practice / sequence in removing them.


Will read again the actuator article and consider options on return in 16 days.

#4 alex.hajek



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Posted 12 August 2013 - 02:24 PM


A MILLION thanks to the guy who originated the post.

Owner of a Fusion Durashift ETS which was stuck in 3rd.I dismantled the actuator, cleaned it, and after reputting the parts together, the engine wouldn't start. So I read this post, opened the wires, and there it was, a little one,broken completely. Soldered together, put everything in place, and it WORKS.

So, bravo one more time!  

#5 wase16ll


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Posted 13 August 2013 - 12:06 AM

glad it helped

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