Hi Everyone,

I have an issue with my Ford Galaxy after I swapped the faulty Powershift gearbox to a manual. Mechanicly everything looks good, I did start the car and did a test drive too. The problem is, I still have some fault codes in DTC even, if I changed the "gearbox" and "gearbox type" in BCMii. 
I did try to update the PCM Firmware to a different one, but it made it worst. I decided to put back the original firmware, but I think I need to modify the PCM's as built data to get rid of TCM related faults because the car still missing the powershift's TCM. I will provide as many details as possible, I hope someone knows how to rectify this issue. 

I was using ChatGpt to help me trough the processes, but I had to find out it doesn't have a clue at the most of the time. The firmware update was it's idea too, then when the resoults didn't match the expectations it just told me to ask for a professional help. I did purchase few different firmwares to try, but the original brings the best resoults. 

Mostly the ABS modul has issues so I did try  ABS Module initialization/relearn from Central Configration but it failed. ---> 
(OK) [16:25:42.066] ABS Module initialization/relearn from Central Configration has been started
(ERR) [16:26:10.415] Service procedure is not supported
(ERR) [16:26:10.416] Service procedure has been interrupted

Car Details: 2013 Ford Galaxy Titanium X; 2.0L TDCI 120kw / 163HP Duratorq TXWA ; vin: wf0mxxgbwmdu03087
PCM: Delphi DCM 3.5 ; Part number: BG91-12A650-FHD ; HW: AG91-12B684-DC ; Calibration: BG91-12A650-FHD ; Strategy: BG91-14C204-FHD ; Secondary Boot Loader: AG91-14C273-AA

I have a Forscan Extended licence and an OBDlink EX adapter. 
These few fault codes comes after DTC clear, later on comes a bit more. I upload the Forscan log files, as built datas from modules too. 

The main fault codes: 

===PCM DTC U0101:00-27===
Code: U0101 - Lost Communication with TCM

===ABS DTC U0401:68-8A===
Code: U0401 - Invalid Data Received From ECM/PCM 'A'

===PBM DTC U2101:00-2F===
Code: U2101 - Control Module Configuration Incompatible

===IPC DTC U0420:68-2B===
Code: U0420 - Invalid Data Received from Power Steering Control Module 'A'

===BCMii DTC C1A41:21-2F===
Code: C1A41 - Clutch Pedal Sensor

Additional Fault Symptom (:21):
- Signal Amplitude Less Than Minimum
( this fault code is on because I did use a wrong type of switch, I should change it to a proper one. It recognise when I press the pedal but still doesn't like it because it's not the original switch. )

Not important or different fault codes, that not related to the problem: 

PCM DTC P246B:00-67 ; HCM DTC C1A05:14-AF ; CMR DTC B100E:87-2F

If someone did do a success gearbox swap on a Ford Galaxy before and knows what is going on now, please help me out this situation. 

A BIG thank you in advance! 
 

forscan dtc log.txt Vehicle Modules Info.txt

I could be wrong, but I reckon:

Remove TCM from vehicle
Fit a donor manual PCM that matches your powertrain's specification
Install a manual firmware into the BCM
Install a manual firmware into the IPC

Not guaranteed, but worth a try

2 hours ago, DaveT70 said:

Not guaranteed, but worth a try

.....but if it all works, quickly buy a lottery ticket while your luck is still in 🎉🎉

Hell of courage to perform such change man... good luck with it.

Long time ago I changed with a really good mechanic, gearbox automatique on a Toyota Corolla. It was the same gearbox, but anyway took two days to change plus a lot of adjustments.

Hi, 

The TCM have been removed anyway because that's a part of the DCT450 Powershi(f)t gearbox. The manual MMT6 gearbox doesn't have a TCM so it's missing. 
 

I can not replace the PCM from a donor car because that's way older, and has a different PCM. But I bought a similar PCM from ebay, that has a manual configuration on it. I downloaded the configuration ( FHF ) and uploaded into my PCM. The resoult was so many fault codes 😂😂 so I did put back the original. 

Now I need to get a manual Galaxy's as built data from somewhere, maybe that should do the job. Maybe not 🙈 

I would pay someone to fix it, rather then just playing with it and waste a lifetime. 

9 hours ago, arklas5025 said:

Now I need to get a manual Galaxy's as built data from somewhere, maybe that should do the job. Maybe not 🙈 

Yes, on a manual PCM, your auto PCM is constantly looking for the TCM

Manual firmware in BCM and IPC too, as mentioned

18 minutes ago, DaveT70 said:

Yes, on a manual PCM, your auto PCM is constantly looking for the TCM

Manual firmware in BCM and IPC too, as mentioned

I have a manual firmware for a PCM, but I am not sure where can I get the firmware for the BCM and IPC. I did change the configuration in BCMii from auto to manual, then the gear selector disappeard from the display as it should. Asking to press the clutch to start, but I am still not sure how to get the proper firmware for them. Could Forscan find them automaticly? 

No, I think you'll need a VIN from a same age car, same spec as yours, but with manual gearbox.

You may even need new, manual, harnesses😬

That's why I said, it may work, maybe not.

I'm just going off from experience of converting an early 90's Sierra from auto to manual and I had to change PCM for manual, but I know modern modules are more complex.

If they're looking for the auto signals (TCM, solenoid body, gear selector etc) it causes issues. Manual firmware will ignore these signals

Try joining the FORScan forums and see if anyone on there has done in, they will advise on what to do

11 hours ago, DaveT70 said:

No, I think you'll need a VIN from a same age car, same spec as yours, but with manual gearbox.

You may even need new, manual, harnesses😬

That's why I said, it may work, maybe not.

I'm just going off from experience of converting an early 90's Sierra from auto to manual and I had to change PCM for manual, but I know modern modules are more complex.

If they're looking for the auto signals (TCM, solenoid body, gear selector etc) it causes issues. Manual firmware will ignore these signals

Try joining the FORScan forums and see if anyone on there has done in, they will advise on what to do

Thank you for the advises. I put this problem on a forscan forum as well.  I did try a manual firmware on my pcm ( not the pcm itself I know) but it didn't solve the problem. I modified the harness as I seen on youtube, there is a guy who made a powershift gearbox swap on a ford focus. I know it's not a galaxy but most of the things are the same. Here is the link: 

This guy know what his doing 😉 but look like still some differences between focus and galaxy. The moduls claiming a communication issue, some invalid data received by a pcm and abs modules. It should worth to try a SW update on them but I like to know exactly what am I doing. A good guess may don't help now, looking for someone who did do exactly this before ( rare a crazy person like me 😅 ) or someone who has knowlage to understand what is going on. I have heard of people who could help trough Teamviewer or something like that. Do you know anyone? 
 

I would definitely ditch the auto PCM for the equivalent manual PCM

52 minutes ago, DaveT70 said:

I would definitely ditch the auto PCM for the equivalent manual PCM

Okay I will try that today afternoon. I have heard, there is a way to reset the abs module in forscan. Other people sais I must unplug the abs module then back on. I will have look that too. 

I'm not sure about that, that may need manual firmware too? Maybe?

4 hours ago, DaveT70 said:

I'm not sure about that, that may need manual firmware too? Maybe?

I think it has the manual firmware on it. BG91-14C204-FHF

So I downloaded the Eeprom data from mine, and uploaded onto a manual pcm. The firmware remain the same.  So the keys and vin should not be different. We will see how it goes. 

13 hours ago, DaveT70 said:

I'm not sure about that, that may need manual firmware too? Maybe?

I pluged in the PCM with an FHF firmware ( should be the manual one ) on it. I have more fault codes now, but mostly the abs complaining. Few new problem came like power steering fault. 
Here is a log if someone would read something before sleep 😉😅 

original_FHF_PCM.txt

They're mainly all "Lost communications with" issues mainly due to the missing TCM & gearbox and shifter I bet.

Maybe all the complaining modules need replacing with manual counterparts or manual firmware installing

 

hi has anyone managed to get it right im considering of doing it