11 hours ago, unofix said:

Then I think you need to find the Drum relearn option in FORScan and follow the instructions exactly. It teaches the gearbox where exactly each gear is. There is a serious amount of clucking while it's in progress. Make sure the parking brake is fully on. 

I've taken a look at the Forscan forum and it says:

1. Download and install latest FORScan version from the official site.

2. Install Extended license as described here:

http://forscan.org/forum/viewtopic.php?f=5&t=836

3. Run FORScan, connect to the vehicle, go to the Service section and run the "TCM Adaptive Learning" function.

4. New menu wlll open, it will show 4 options: Perform Transmission Range sensor Adaptive Learning, Verify Transmission Range sensor Adaptive Learning, Perform Shift Drum Adaptive Learning and Perform Clutch Adaptive Learning. First 3 operations are relatively simple and must be used to check the adapter's ability to perform the function. Last one is the most complex.

I only recall 3 options: reset module, and two clutch programs. Can't remember their names. But I'll look again.

 

Thanks for the input!

2 hours ago, Meekoblue said:

2. Install Extended license as described here:

You don't need an Extended Licence to do Service Procedures.

Its OK I have an extended licence anyway. I just don't see anything that mentions "drum".?

OK took a look as Forscan again:

Only offers 

clutch system learn

shift fork system learn

TCM Module reset

A few niggles attended to and when gearbox warm carried out:

Quote

(OK) [12:05:11.305] TCM Clutch System Learn has been started
(WARN) [12:05:11.366] Checking vehicle conditions...
(OK) [12:08:27.987] Service procedure completed successfully.
(OK) [12:11:23.025] TCM Clutch System Learn has been started
(WARN) [12:11:33.023] Checking vehicle conditions...
(WARN) [12:11:55.110] Performing function: Clutch Stroke Learn
(OK) [12:12:03.992] Clutch Stroke Learn - OK
(WARN) [12:12:03.994] Performing function: Clutch Ventilation Learn
(OK) [12:12:54.082] Clutch Ventilation Learn - OK
(WARN) [12:12:54.087] Performing function: Clutch Boost Learn
(OK) [12:13:47.056] Clutch Boost Learn - OK
(OK) [12:13:59.747] Please wait...20 seconds
(OK) [12:14:23.793] Service procedure completed successfully.
(OK) [12:14:42.540] TCM Shift Fork System Learn has been started
(WARN) [12:14:48.135] Checking vehicle conditions...
(WARN) [12:14:59.480] Performing function: Shift Fork Plausibility Learn
(OK) [12:15:04.650] Shift Fork Plausibility Learn - OK
(WARN) [12:15:04.654] Performing function: Shift Fork Learn    
(OK) [12:16:45.344] Shift Fork Learn     - OK
(OK) [12:16:53.899] Please wait...20 seconds
(OK) [12:17:19.680] Service procedure completed successfully.

So we are about to give it a try on the motorway! Keep off the M60 for the next 2 hours....

2 hours ago, Meekoblue said:

So we are about to give it a try on the motorway! Keep off the M60 for the next 2 hours....

Good Luck 👍

Well that was interesting.

Done about 25 miles mixed driving.

Transmission Limited Function and no odd gears about 4 times, buy could be cleared by stopping, key off, key on and away we go again. Always when it wants to change up a gear. Should be solenoid D error but no errors in Forscan. Once it errors it wont be persuaded to go into an odd gear unless key off/key on.

However! About 12 miles into the ride I had an idea- put it in sport/manual mode and manually change up (it seemed happy enough to change down itself). No errors over 12 miles. Hardly an exhaustive test but interesting.

Also noted when reversing back onto driveway the selector lever does P-R-N-D and so it should EXCEPT in reverse it does D-D-N-R/P !!!

By that I mean it feels to have 5 detent positions on the way back and the first two are both engaging drive and trying to move. Neutral does as it should but Reverse is tricky and it can end up in Park! So clearly I have a linkage/selector problem somewhere. Going to put Forscan on and monitor the gear lever positions first and fiddle with the linkage somehow.

For what it's worth it looks like the D-D-N-R/P selections and physical detent positions do correspond with those actions and the illuminated letters on the lever trim/Convers+ so I feel its a physical problem that must be eliminated before I continue.

The other thing I'm thinking is gear changes a fine manually but fail automatically, so could the TCM be at issue here? Maybe it needs wiping and reloading firmware? If it was truly a failing solenoid or valve surely it fail manually too? Unless it's to do with the physical postition of the lever in S position....

 

Sorry for the wall of text. Trying to reason it out to myself. And also hopefully save someone else the headache. As ever all comments appreciated! 

 

Edited November 20, 20232 yr by Meekoblue
updated

Had a play with gear linkage but nothing wrong.

Went for a drive and Transmission Function Limited almost immediately. This time solenoids d & e.

Key off.key on. Into sport mode and I've done over 40 miles from city to motorway without error, and with some lovely smooth gear shifting.

 

We are convinced the error is the range sensor wheel still misaligned with the selector arm. So giving it a couple of days then will drain oil and take off plastic cover AGAIN to reposition the wheel.

 

I understand about the pin in the hole on the wheel. What I don't get and could do with some confirmation of: the selector lever seems to have 5 detent positions so I'm guessing P R N D something else? I thought it was only 4. And I'm sure I had the selector in the last position believing it to be 4th or D when I withdrew the range sensor wheel - which I'm now believing I've put back in the 5th or ? Position not D.

I'm guessing the range sensor is borderline D / N and when shifting gears it disrupts the selection so the TCM goes into limp mode to protect itself?

Will know next week! Having a go on Monday. Had enough of the s-max this week.

Meeko

Does the info on pages 10 and 11 of the manual I sent you offer any help

3 hours ago, TrevorB said:

Meeko

Does the info on pages 10 and 11 of the manual I sent you offer any help

Yes!!!

There's so much info I've seen that I'm missing stuff. Thanks for pointing it out!

Well. Getting there. 

Just taken apart for 3rd time. Yep it's a 5 position lever and I'd aligned to the 5th not Drive. Doh!

Pin in place (for European viewers an M3.5 screw fits perfectly) 

With wheel lined up, it was just a matter of jigglng the lever for the geared lever to fit the toothed wheel and bingo! screw the bugger down before it moves! 

Needs more oil (on order) and another relearn in Forscan but i think were getting there.

Conclusion: I think we've sorted it now.

No transmission errors. No issues with strange shift lever positions! Just a few ropey gear changes in drive, probably needs a re-learn again no all is aligned. Will do after coffee...

For the interested I've prepared a a how-to (6page pdf) step by step distillation of all the above in case it might be a help to another powershift victim.

 

Not sure if I should start a new thread just with the how-to, in case reading through all this causes someone to lose the will to go on! Any thoughts?

6DCT450.PDF

Edited November 23, 20232 yr by Meekoblue
Corrections

Thats great stuff Meeko'

Later today I will link this thread and it's PDF across to the other good forum - "Talk Ford" - put it in the Mk4 Mondeo Drivetrain section where there is also quite a lot of info on the powershift 6DCT450.

I am sure it will help others in the future

1 hour ago, TrevorB said:

Thats great stuff Meeko'

Later today I will link this thread and it's PDF across to the other good forum - "Talk Ford" - put it in the Mk4 Mondeo Drivetrain section where there is also quite a lot of info on the powershift 6DCT450.

I am sure it will help others in the future

I'm glad you like it. Feel free to redistribute.

On 11/23/2023 at 8:36 AM, Meekoblue said:

Conclusion: I think we've sorted it now.

No transmission errors. No issues with strange shift lever positions! Just a few ropey gear changes in drive, probably needs a re-learn again no all is aligned. Will do after coffee...

For the interested I've prepared a a how-to (6page pdf) step by step distillation of all the above in case it might be a help to another powershift victim.

 

Not sure if I should start a new thread just with the how-to, in case reading through all this causes someone to lose the will to go on! Any thoughts?

6DCT450.PDFUnavailable

Hey I have been reading this thread with much interest after buying a galaxy which currently has “issues” lol

im about to engage myself in this exact same down the rabbit hole process so this thread has given me a great insight 

 

On 11/12/2023 at 1:20 AM, Meekoblue said:

Hello

Ive been having problems with the Powershift transmission for about 3-4 weeks with increasing frequency, code p2715 solenoid D

So ive bitten the bullet and tackled the repair.  I intended to document here the progress and outcome.

Ive found some brilliant youtube videos by an Australian that shows pretty much everything. Ill link them in later.

Youtube vid 1 of 3  part 2  part 3  6DCT450 manual

To remedy this problem the solenoid pack needs to be opened up and cleaned. To do so the following was necessary.

Car on ramps. Battery disconnected. Air filter box removed. Gearbox oil drained from both drain plugs underneath and ideally radiator drained* I learned my mistake later. Remove the round plug from the gearbox

Underneath remove the large diameter metal pipe from in front of the solenoid cover. Next you need as much access to the mecatronics by removing the hose from the oil cooler and lower radiator... Do it now.

Remove the plastic cover from the solenoid pack. this is secured with Torx T30s and 3 bolts.

Remove the 11 Torx T30 screws from the pack - 7 on your left, 4 on your right. I could do all but lowest left from above.

Tie/secure all the wires and hoses. I cant stress this enough, you need every mm of access to get the body out.

Unclip the gear selector arm by pressing the button on the arm, and lifting off, then move selector to D position.

Remove the bolt next to the selector arm.

Remove the 2 Torx T25 screws at the top of the pack going through the black plastic either side of the round connector.

GENTLY remove the small black connector with three wires next to the round connector. Be gentle with this its the speed sensor.

now with a flat bladed screwdriver tease the pack back from the gearbox. there are two long metal guide pins, and two metal gaskets. the guide pins are essential to help you clear the gearbox with the protruding black sensors of the mechatronics. youll see why you need EVERY spare mm of clearance.

I found the best way was to draw it back to the radiator, then jiggle around so the sensors were half out and above the gearbox body, then tilt towards the windscreen and clear the lower sensors. it can be done from above but be prepared for a struggle and it gets damn heavy while struggling! 

Breath a sigh of relief when out and congratulate yourself!

Clean up etc. Be very careful of the black round connector- it has a delicate ribbon cable. 

 

Now with the sensors upwards and round connector to your left, youll find about 8 Torx T30s all short except one very long on the extreme right/closest to you.

Lift off this plate and set aside carefully.

The body now gives access to the solenoids. Youll need Torx T15 bit at least 50mm long to reach the two screws securing each solenoid. Be careful not to strip the head of the screw, theres no access to get it out!

Take one out at a time. there are 2 of one type, 2 of another and 5 of a third type. 

I took one out, and applied an 8 volt supply via small test leads to each solenoid, and cheked for movement - the 5 are hardly discernable but the other 2 and 2 are very noticable.  Once youre sure it works, clean it up- I used WD40 contact cleaner, then compressed air, then used a ten quid watch demagnetiser from Amazon to demagnetise the solenoid body so the plunger activates only when a charge is applied, as it should.

Clean up and reinsert.

Refitting is reverse of above.... so far!

So far: Gearbox solenoid pack removed (took 5 hours of toil and strong language) solenoids cleaned, demagnetised and tested, and restored to the pack. Wont be able to refit until monday, wish me luck!

 

I'll post an update Monday evening with the verdict.

EDIT:

How-to:

 

 

 

6dct450-470-service-menu.pdf

Hello. The other day I encountered the same error. I tried everything that was said here. Did not help. But I solved the problem this way. I replaced the magnetic wheel from the gear position sensor. I took my sensor and a new sensor, using a metal blade from a construction knife, and determined that my wheel attracts this blade twice as weakly. After installing a new wheel, the problem went away. I recommend it as an option.

Very interesting and useful information Vlad, thank you

Many thanks for the info on the range sensor PRNDL . I rebuilt my 6dct450 gearbox and had the same issue. I set the range selector in the L position insead of the D and had same issues

However after correcting range sensor problem I had further complications re 6dct450. The clutch adaptations passed but the shift fork adaptation failed with error. "shift fork learning error". The diagnostic code is thus P0949. Any idea how to troubleshoot? 

live monitoring of TCM correctly identifies gearbox in positions NEUTRAL, Reverse ,Drive, manual select gears 1 & 2. Wont select up beyond 2. Don't know if this is because car is off ground with parking brake off and not on the road

Done a full rebuild. Both clutch system learn and shift fork system learn fail after like 5-7%. If I reset DTC codes and do TCM module reboot the first error is always P0949 and after trying to perform the procedures I'll get a bunch of other codes like P284A Shift Fork B stuck. Gearbox was functioning well before rebuild (until the vibration damper plastic bits spread all over and blocked everything). I've cleaned everything, new clutch plates, tested all the solenoids, put in new pistons, etc.

Dashboard identifies gearbox in gear 7 while in manual select with engine running and upshifting shows up as gear 6 (sometimes won't shift and just shows 7). With engine off it shows gear 1. All other positions are identified correctly. During assembly the 3.5mm drill bit I've used to put in the hole would always end up at a slight angle - offset probably by about 15 degrees from vertical, not sure if that's normal. Also the new pistons are very tight, once inserted pulling them out is not possible by hand, but they come out easily with some compressed air and slide in by hand with pressure. Is that normal? I've never done anything like this before so not sure.

Forscan doesn't really tell why the procedure failed, just says ERR. Is there any way to get more information why it's failing or is it simply because of the DTCs? Any ideas on how to proceed?