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6DCT250 HOP SO POWERSHIP FOCUS-FIESTA SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Specifications Transmission fluid WSS-M2C200-D2
6DCT250 HOP SO POWERSHIP FOCUS-FIESTA SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Specifications Transmission fluid WSS-M2C200-D2 Capacities Litres Transmission fluid - Dry 1.8 Transmission fluid - Service 1.5 General Specifications Item Specification mm (in) Clutch Clutch 1 26 (1.023) Clutch 2 15 (0.59) Shift fork and hub sleeve clearance Reverse/4th gear shift fork and hub sleeve Maximum 1.85 (0.072) Standard 0.75-1.25 (0.029-0.049) Clearance between 1st/5th gear shift fork and hub sleeve Maximum 1.85 (0.072) Standard 0.75-1.25 (0.029-0.049) Clearance between 3rd gear shift fork and hub sleeve Maximum 1.725 (0.067) Standard 0.625-1.125 (0.024-0.044) Clearance between 2nd/6th gear shift fork and hub sleeve Maximum 1.725 (0.067) Standard 0.625-1.125 (0.024-0.044) Synchronizer ring clearance, clearance between synchronizer ring and flank surface of gear Minimum 1.30 (0.051) Differential Shim Selection Chart Tool reading mm (in) Shim Thickness mm (in) 0.500-0.550 (0.0196-0.0216) 0.500 (0.0197) 0.551-0.600 (0.0216-0.0236) 0.550 (0.0217) 0.601-0.650 (0.0236-0.0255) 0.600 (0.0236) 0.651-0.700 (0.0256-0.0275) 0.650 (0.0256) 0.701-0.750 (0.0275-0.0295) 0.700 (0.0276) 0.751-0.800 (0.0295-0.0314) 0.750 (0.0295) 0.801-0.850 (0.0315-0.0334) 0.800 (0.0315) 0.851-0.900 (0.0335-0.0354) 0.850 (0.0335) 0.901-0.950 (0.0354-0.0374) 0.900 (0.0354) 0.951-1.000 (0.0374-0.0393) 0.950 (0.0374) 1.001-1.050 (0.0394-0.0413) 1.000 (0.0394) 1.051-1.100 (0.0413-0.0433) 1.050 (0.0413) 1.101-1.150 (0.0433-0.0452) 1.100 (0.0433) 1.151-1.200 (0.0453-0.0472) 1.150 (0.0452) 1.251-1.300 (0.0492-0.0511) 1.200 (0.0472) Gear Ratio Gear Ratio Final Drive Overall Ratio Reverse 3.508 4.35 15.270 1st 3.917 3.89 15.254 2nd 2.429 3.89 9.459 3rd 1.436 4.35 6.250 4th 1.021 4.35 4.446 5th 0.867 3.89 3.375 6th 0.702 3.86 2.735 Transmission Description — Overview General The 6DCT250 is an electronically controlled 6-speed manual transmission which performs in the same manner as a conventional automatic transmission while retaining the fuel efficiency of a manual transmission. The 6DCT250 is equipped with two input shafts, a hollow and a solid input shaft. Torque is transferred from the engine to the two input shafts via a dry double clutch unit. There are two independent clutches in the clutch unit which are engaged and disengaged by two clutch actuator motors and actuators. The clutch actuator motors are controlled by the TCM. Having a double clutch and input shaft system enable the 6DCT250 to simultaneously select the next gear up or down depending on shift direction, providing seamless shifting through the 6 forward gears. Gear selection is controlled by the TCM using two integrated electric motors to rotate a series of gears and shift drums which in turn move the shift forks selecting the appropriate gear. The TCM utilizes a number of sensors mounted on the transmission and data received via the CAN to maintain the correct operation of the transmission. Transmission Description — Component Location Item Description 1 Transmission Vent Assembly 2 Transmission Clutch Actuator Motor #1 Comments: Gears 1st, 3rd and 5th 3 TCM 4 TR sensor 5 Transmission Outer Manual Lever 6 Transmission Halfshaft Seal 7 Transmission OSS Sensor 8 Transmission ISS Sensor #1 9 Transmission ISS Sensor #2 10 Transmission Clutch Actuator Motor #2 Comments: Gears 2nd, 4th, 6th and R Item Description 1 Transmission Fill Plug 2 Transmission Drain Plug 3 Transmission Halfshaft Seal Transmission Description — System Operation and Component Description System Operation Overview Item Description 1 Engine 2 Clutch unit 3 3rd, 4th, reverse and park gear output shaft 4 Input shaft (solid shaft) (1st, 3rd, 5th) 5 1st, 2nd, 5th and 6th gear output shaft 6 Differential 7 Input shaft (hollow shaft) (2nd, 4th, 6th, R) In principle, the transaxle comprises two independent gear trains. During driving, one gear train is always positively connected and the other set is already engaged in the oncoming gear (although the clutch for this gear is still open). Transaxle Design Item Description 1 Input shaft (solid shaft) (1st, 3rd, 5th) 2 Output shaft (3rd, 4th, R and Park) 3 Differential 4 Final drive / ring gear 5 Input shaft (hollow shaft) (2nd, 4th, 6th and R) 6 Output shaft (1st, 2nd, 5th and 6th gear) The name 6DCT250 stands for: 6 = Six gears D = Dual C = Clutch T = Transaxle 250 = Torque (Nm) This transaxle is regarded as a further development of the 6DCT450 PowerShift transaxle, instead of utilising the "wet-running" (in fluid) plate assemblies of the clutch, the 6DCT250 features a compact dry dual system clutch. Ford is installing the transaxle for the first time in the Fiesta (B299), model year 2010.5 (04/2010-) with 1.6L Duratec engine. It will be used universally in further vehicle lines. The transaxle features two nested input shafts driven by a compact dry dual clutch system. These two shafts are used in concert to provide seamless shifting through the six available ratios with overdrive in the two top gears. As each gear is selected, the appropriate clutch is activated to drive the vehicle. Each consecutive gear is then preselected for the next "shift" operation as power is shifted from one clutch to the other and back again whilst moving up and down through the individual gears. The 6DCT250 transaxle provides the smooth application of power as per the 6DCT450, but with the advantages in efficiencies found only in a manual transaxle. By delivering power with a dual "dry" clutch system, fluid volume is limited to less than 2 litres as compared to the conventional automatic transmission. The actuation of the clutch system is controlled by a dedicated computer through two individual electronically driven clutch motor and actuator systems. The selector lever has the following functions: P - Park position R - Reverse position N - Neutral position D - Electronic control of the transmission ratio using the TCM (Transmission Control Module) If the selector lever is in the "P" position and the vehicle has been switched off, first gear and reverse gear will be engaged via the TCM. This results in a faster response after the starting process. Special features of the transmission include: 6 gears plus reverse gear Compact front transverse installation Dry clutch Internal electronic gearshift mechanism Intelligent gear change control Specification Description Ford PowerShift (6DCT250) Weight 73 kg Rotational torque 250 Nm Clutch Dry clutch Gears Six forward gears, one reverse gear Fluid specification WSS-M2C200-D2 (BOT350-M3) World Manufacturer GETRAG Transmission GmbH Dual Clutch Design Item Description 1 Dual clutch unit 2 Clutch actuator 1 3 Guide tube 4 Clutch actuator 2 5 Engagement bearing 6 Retaining ring Electronic clutch actuator motors are used to actuate each clutch in the transmission. The motors work independently of each other. The clutch actuators are independent systems within the clutch housing which apply an axial force operating against the clutch diaphragm springs causing their respective clutch to engage. When a clutch is fully engaged, the clutch actuator motor provides the holding torque. During disengagement the clutch actuator motor relaxes to it's rest position. When engaged the applied force is directed back into the transmission through the hollow input shaft; unlike a standard manual transmission, no thrust is applied to the engine crankshaft. A clutch 'touch point' position must be established by a learning algorithm within the system software. Establishing the touch point is the system's method for ensuring that the clutch actuation system is properly calibrated. This is necessary so that clutch engagement can be controlled correctly by the transmission control module (TCM) and both engaged and released steps are at the required torque capacity and within the required time. Item Description [...]... vehicle moves, the tension of the torsion spring (3) causes the park lock pawl (5) to engage in the next tooth gap in the park lock gear (4) DIAGNOSIS AND TESTING Diagnosis By Symptom General Equipment Ford diagnostic equipment Vehicle communication module (VCM) Symptom Chart Clutch Operation Symptom Harsh or Soft/delaye d engagemen t or shifts Possible Sources Action Clutch Adaptive Learn Go to... Transmission/Transaxle — Vehicles With: 6-Speed Automatic Transaxle 6DCT250, DISASSEMBLY) Diagnostic Parameters Identification (PID) Chart NOTE: The following general PID list may be of use to the technician when exercising output state control: Accessing PIDs PIDs 1stBLCK_GR_JMP 1stBLOCK_TMP PID Description 1st Gear Is Blocked Due To Gear Jump Occurred 1st Gear Is Blocked Temporarily Protect Mode 2ndBLCK_GR_JMP... TR_CRANK_F Park Neutral Starter Enable Output Fault Detected TR_SUPPLY_F Transmission Range Supply Voltage Output Fault TRAN_RAT Transmission Gear Ratio Diagnostic Trouble Code Charts General Equipment Ford diagnostic equipment Vehicle communication module (VCM) Diagnostic Trouble Code (DTC) Chart Five Digit DTC Description Condition Symptom Action P06A Sensor Reference Input shaft speed Disabled 3rd . 6DCT250 HOP SO POWERSHIP FOCUS- FIESTA SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Specifications. 6DCT250 features a compact dry dual system clutch. Ford is installing the transaxle for the first time in the Fiesta (B299), model year 2010.5 (04/2010-) with