DIY Powershift DCT fluid change Mk4 Mondeo - Drivetrain (Mk4 Mondeo) - TalkFord.com

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DIY Powershift DCT fluid change Mk4 Mondeo


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#1 Speedlimit

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Posted 28 January 2015 - 12:57 AM

*
POPULAR

FLUID CHANGE PROCEDURE
Getrag 6DCT450 on MONDEO 2007-2014


The following information was written for my own use
(I'll have forgotten it by the next service otherwise)
and has worked fine for me. I used the FUCHS fluid
which is recommended by FUCHS for the Ford DCT, did mine
a year ago now and no problems.
I had access to a Ford factory manual, and got some hints
from a Volvo training video which I can no longer find.
The transmission has two main chambers which end up
with different fluid levels, hence the specific procedure
for filling outlined below.
The filter housing requires a 32mm tool for removal.
I use a shortened ring spanner, 200mm overall.
Filling requires a funnel with tube extension.
Not having a hoist, the hardest part for me
was getting the car raised AND LEVEL. Uni-body
construction means only the four designated jacking points
should be used, (according to Ford documentation).
I used a home-made beam across the rear sills to raise the rear
in one go, being a bit concerned about twisting
the body. A bit at a time either side might be the way.
I also use trolley jacks with a steel strut inserted from the axles
to the jack head which converts the jack into a safety stand.
I guess two people could jack the the car up evenly by working together.
Or twisting might not be an issue, I don't know.
If anyone has anything to add or correct that would be good.
 
 

STEP 1: PREPARATION

GETRAG 6DCT450 TRANSMISSION FLUID
Ford specification WSS-M2C936A.
OR
FUCHS part number 4377
FUCHS Titan DCTF
Transmission filter kit.
Temperature of transmission fluid: 35-45 degrees C.
Transmission must not be in limp mode or have DTC's.
Remove air filter housing etc to gain access to filler plug.
Raise car to a convenient height.
Note: CAR MUST BE LEVEL.
Remove undertray (10mm socket)
Place waste container. (About 5-6 litres should come out)
Remove passenger side wheel to gain access to the filter.
Remove two nuts and three screws and clamp the plastic guard
out of the way.
Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.


STEP 2: DRAIN THE OLD FLUID

There are 3 drain plugs before 02/2009, 2 drain plugs after.
Remove all the 8mm hex socket drain plugs.
Remove the level check plug on the side of the transmission.
A two-foot long extension with a universal joint makes it easy.         
After the fluid has drained replace the drain plugs.
Leave the check level hole open.
Unlock and remove the filter.
Note: The filter housing has a plastic locking clip, a small
plastic wedge is handy to hold it open.


STEP 3: FILL WITH FRESH FLUID

Prime the new filter with fluid and install.
Fill transmission with 5.5 litres of fluid.
Install the filler plug.
Install the level check plug.


STEP 4: LEVEL ADJUSTMENT

Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.

Remove the level check plug.
Allow fluid to drain until it begins to drip.

Note: THE FLUID THAT ESCAPES DIRECTLY AFTER
THE FLUID LEVEL CHECK HOLE IS OPENED
IS NOT AN INDICATION OF A CORRECT FLUID LEVEL.
FLUID MUST BE ADDED THROUGH THE FILLER OPENING
WITH THE LEVEL CHECK HOLE OPEN UNTIL THE FLUID AGAIN
RUNS OUT AT THE LEVEL CHECK HOLE, AS FOLLOWS:

Top up via filler hole until fluid flows again
through the level check hole, allow to drain again
until it begins to drip.

Install level check plug and filler plugs.
Put the rest back together and the job is done.








 
 


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#2 Speedlimit

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Posted 29 January 2015 - 01:56 AM

I'm replying to my own post here, just to clarify. 

 

Just in case anyone is wondering, I don't see how the transmission having two chambers relates to the

specified procedure. That's how it's described in the Ford manual I mentioned. Speaking of manuals, the Haynes manual I have doesn't cover the Powershift transmission. My information is from a

Ford (copyright) source. I'm not a mechanic, but have been keeping various Fords alive for about 40 years.

 

 

It's really quite easy to change the fluid, and you will save heaps $$s

The FUCHS fluid was about half the price of Ford here in Australia. My two Mondeos have been running fine

after a year with FUCHS fluid. One LX diesel wagon and one zetec diesel wagon. I prefer the LX, it has an old fashioned temp gauge, and parking isn't a problem in the bush.  I use Forscan to check the temperature of the gearbox, but if you like a warm bath,

that's about 40 centigrade.

 

Cheers



#3 Speedlimit

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Posted 29 January 2015 - 10:16 PM

Powershift DCT Fluid change

ADDITIONAL NOTES

The fluid capacity is 6 litre, including filter.
The filter holds about 0.1 litre.
So 6 litre required.
The Ford fluid came in 1 litre bottles.
The Fuchs fluid came in 4 litre containers.
Prime the filter, then fill the box with 5.5 litres.
Use the remaining 0.4 litres to adjust the level.

I used the 8 litre option with 2 containers of fluid.
That explains why I left the level check hole open
during filling: I thought I'd let a couple of litres
flush through. So normally the level check plug
would be replaced for the initial fill and
engine running circulation, then removed for the level check.
Revised procedure notes to follow.

Cheers



#4 Speedlimit

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Posted 29 January 2015 - 10:18 PM

*
POPULAR

FLUID CHANGE PROCEDURE Rev. 1
Getrag 6DCT450 on MONDEO 2007-2014




STEP 1: PREPARATION

FLUID CAPACITY: 6 litres.

GETRAG 6DCT450 TRANSMISSION FLUID
Ford specification WSS-M2C936A.
OR
FUCHS part number 4377
FUCHS Titan DCTF
Transmission filter kit.
Temperature of transmission fluid: 35-45 degrees C.
Transmission must not be in limp mode or have DTC's.
Remove air filter housing etc to gain access to filler plug.
Raise car to a convenient height.
Note: CAR MUST BE LEVEL.
Remove undertray (10mm socket)
Place waste container. (About 5-6 litres should come out)
Remove passenger side wheel to gain access to the filter.
Remove two nuts and three screws and clamp the plastic guard
out of the way.
Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.


STEP 2: DRAIN THE OLD FLUID

Engine off.
There are 3 drain plugs before 02/2009, 2 drain plugs after.
Remove all the 8mm hex socket drain plugs.
Remove the level check plug on the side of the transmission.
A two-foot long extension with a universal joint makes it easy.         
After the fluid has drained replace the drain plugs.
Unlock and remove the filter.
Note: The filter housing has a plastic locking clip, a small
plastic wedge is handy to hold it open.


STEP 3: FILL WITH FRESH FLUID

Prime the new filter with fluid (about 0.1 litres) and install.
Fill transmission with 5.5 litres of fluid.
Install the filler plug.


STEP 4: LEVEL ADJUSTMENT

Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.

Remove the level check plug.
Allow fluid to drain until it begins to drip.

Note: THE FLUID THAT ESCAPES DIRECTLY AFTER
THE FLUID LEVEL CHECK HOLE IS OPENED
IS NOT AN INDICATION OF A CORRECT FLUID LEVEL.
FLUID MUST BE ADDED THROUGH THE FILLER OPENING
WITH THE LEVEL CHECK HOLE OPEN UNTIL THE FLUID AGAIN
RUNS OUT AT THE LEVEL CHECK HOLE, AS FOLLOWS:

Top up via filler hole until fluid flows again
through the level check hole, allow to drain again
until it begins to drip.

Install level check plug and filler plugs.
Put the rest back together and the job is done.

 


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#5 TreborB

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    8 gears or more please

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Posted 30 January 2015 - 09:36 AM

Hi Reg, that's really good info. Many thanks. Also I always wondered why I could only find 2 drain plugs!! now I know.
I will need the fluid changing on mine very soon. Its overage but only 30,000 miles and never does short stop start runs. Mainly motorway use

Edited by TreborB, 30 January 2015 - 09:36 AM.

BMW 320i M Sport 2019 Mineral Grey, Steptronic 8 speed ZF Auto

( Sorry but NO 2.3 Ecoboost 8 Speed Auto Mondeo's to be found!)

 

Focus 2018 Mk3.5, 1 Litre Ecoboost 140ps ST Line, SYNC3 Sat Nav, Parking Sensors, Colour Magnetic - Gifted to the Wife! Then Sold Aug 2019

 

Mondeo Mk5 Titanium 2L Ecoboost 240ps, X Pack, Body Kit, Rear Spoiler, 19" Alloys, LED Headlamps, Sony 12 Spkr Audio, Park Assist, Winter Pack, Rear Camera, Magnetic, Built Sept 2015,Sold Oct 2018.

Mondeo TitaniumX Sport 240ps 2L Ecoboost Powershift 2011 - Sold 2016 But Never Forgotten.

2007 - 2010, 4 New Focus ST225s


#6 Speedlimit

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Posted 30 January 2015 - 11:42 PM

OK, I missed a 'level check hole' deletion in the last edit. All good now I hope. Rev. 2 follows.


FLUID CHANGE PROCEDURE Rev. 2.
Getrag 6DCT450 on MONDEO 2007-2014




STEP 1: PREPARATION

FLUID CAPACITY: 6 litres.

GETRAG 6DCT450 TRANSMISSION FLUID
Ford specification WSS-M2C936A.
OR
FUCHS part number 4377
FUCHS Titan DCTF
Transmission filter kit.
Temperature of transmission fluid: 35-45 degrees C.
Transmission must not be in limp mode or have DTC's.
Remove air filter housing etc to gain access to filler plug.
Raise car to a convenient height.
Note: CAR MUST BE LEVEL.
Remove undertray (10mm socket)
Place waste container. (About 5-6 litres should come out)
Remove passenger side wheel to gain access to the filter.
Remove two nuts and three screws and clamp the plastic guard
out of the way.
Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.


STEP 2: DRAIN THE OLD FLUID

Engine off.
There are 3 drain plugs before 02/2009, 2 drain plugs after.
Remove all the 8mm hex socket drain plugs.    
After the fluid has drained replace the drain plugs.
Unlock and remove the filter.
Note: The filter housing has a plastic locking clip, a small
plastic wedge is handy to hold it open.


STEP 3: FILL WITH FRESH FLUID

Prime the new filter with fluid (about 0.1 litres) and install.
Fill transmission with 5.5 litres of fluid.
Install the filler plug.


STEP 4: LEVEL ADJUSTMENT

Engine running, brake pedal applied, select all gear positions
for 20 seconds each. Return to PARK.

Remove the level check plug.
A two-foot long extension with a universal joint makes it easy.
Allow fluid to drain until it begins to drip.

Note: THE FLUID THAT ESCAPES DIRECTLY AFTER
THE FLUID LEVEL CHECK HOLE IS OPENED
IS NOT AN INDICATION OF A CORRECT FLUID LEVEL.
FLUID MUST BE ADDED THROUGH THE FILLER OPENING
WITH THE LEVEL CHECK HOLE OPEN UNTIL THE FLUID AGAIN
RUNS OUT AT THE LEVEL CHECK HOLE, AS FOLLOWS:

Top up via filler hole until fluid flows again
through the level check hole, allow to drain again
until it begins to drip.

Install level check plug and filler plugs.
Put the rest back together and the job is done.
 



#7 Speedlimit

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Posted 31 January 2015 - 03:14 AM

Trevor, Age might be a factor in the condition of the fluid. I don't know.

It's my impression the fluid is a bit complicated.

It has to do two seemingly conflicting jobs.

It needs to lubricate the gears and bearings, and it has to

allow the clutch to work without slipping.

 

Anyway it's fairly easy to change, just a tad expensive.

I think it was about AUD $360 just for the fluid at Ford.

That's why I switched to the FUCHS, about half the price.

It's sometimes recommended to flush the gearbox when changing brands.

Doing it by simply pouring more fluid through is probably futile.

I guess you'ld really need to do the change twice, expensive.

I didn't and so far so good, after a year.

Maybe the fluids are made in the same factory anyway!

 

The fluid is also stated on the label to be toxic to the environment, so 'dispose of thoughtfully'

 

Cheers



#8 TreborB

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    8 gears or more please

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Posted 31 January 2015 - 03:51 PM

No worries Reg. I will be doing mine in another few weeks once our winter is on the way out. I am up to speed on most technical things including environment issues as I am ex factory trained Jaguar Cars mechanic (technician title these days!)

It will be done by my long term friend and also ex Jaguar and Range Rover Technician. He has his own small business, always fully booked, and never has had to advertise. Obviously we never take our vehicles to a main dealer. It is nothing to do with money. Just want someone who really cares about my car to work on it


BMW 320i M Sport 2019 Mineral Grey, Steptronic 8 speed ZF Auto

( Sorry but NO 2.3 Ecoboost 8 Speed Auto Mondeo's to be found!)

 

Focus 2018 Mk3.5, 1 Litre Ecoboost 140ps ST Line, SYNC3 Sat Nav, Parking Sensors, Colour Magnetic - Gifted to the Wife! Then Sold Aug 2019

 

Mondeo Mk5 Titanium 2L Ecoboost 240ps, X Pack, Body Kit, Rear Spoiler, 19" Alloys, LED Headlamps, Sony 12 Spkr Audio, Park Assist, Winter Pack, Rear Camera, Magnetic, Built Sept 2015,Sold Oct 2018.

Mondeo TitaniumX Sport 240ps 2L Ecoboost Powershift 2011 - Sold 2016 But Never Forgotten.

2007 - 2010, 4 New Focus ST225s


#9 peterpk

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Posted 02 February 2015 - 10:54 AM

Thank you very much finnaly the post I've been looking for months I can't wait to do it myself. At the garage it was costing me around £350.
Thank you thank you thank you :-)

#10 mike wilson

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Posted 02 February 2015 - 02:02 PM

It's sometimes recommended to flush the gearbox when changing brands.
Doing it by simply pouring more fluid through is probably futile.
I guess you'ld really need to do the change twice, expensive.
I didn't and so far so good, after a year.


Or......

http://www.talkford....06e-oil-change/




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