Mark 2.5 Kuga and Powershift

keithmac · 2025-09-28T09:25:43-0400

Getrag Ford Transmissions build all the Powershift gearboxes, the early Volvo 'box is identical to the Ford one, built in the same factory with the same parts..

@Dupont , your Euro6 180 has the later revised gearbox with the external DMF.

This is the main failure point of the early gearboxes, ours was only 60,000 miles old when it started playing up..

Dupont · 2025-09-28T09:45:34-0400

keithmac said:
Getrag Ford Transmissions build all the Powershift gearboxes, the early Volvo 'box is identical to the Ford one, built in the same factory with the same parts..

@Dupont , your Euro6 180 has the later revised gearbox with the external DMF.

This is the main failure point of the early gearboxes, ours was only 60,000 miles old when it started playing up..

View attachment 25618

Thanks for this @keithmac. So, Ford did an improvement on the 6DCT450 before they introduced the 6DCT451? I think that is the bit I don't fully understand.

I just thought all of the improved boxes were the 6DCT451.

sooty2055 · 2025-09-29T11:02:32-0400

RonnieM said:
19 plate will be the late mk2 uplift before the mk3……the mk2 180 uplift (2016 onward) powershift is fine but the box needs a service every 3yrs/36k, I wouldn’t buy without proof of it being done, just for peace of mind
It was the 2013-2014 boxes that had the problem with plastic parts

My 19 plate 2.0 awd is a sealed box ,so worth checking as Ford would have to fix it .

smartguy69 · 2025-09-29T14:44:13-0400

davidjohn said:
He told me the frighteners had been put on owners and was blown out of proportion as a lot of internet nonsence is,

The "frighteners" for many is reality. Here's another one. Failure of the early powershift in not internet nonsense at all. I lost count now of the number of failures on here.

https://www.kugaownersclub.co.uk/threads/new-member-and-ford-kuga-2013-automatic.34121/?post_id=357564#post-357564

Terrier50 · 2025-09-29T16:06:07-0400

Do I need to worry with mine?

NigelB · 2025-09-29T16:08:27-0400

Terrier50 said:
Do I need to worry with mine?

Two words. Get Rid.

NigelB · 2025-09-29T16:09:44-0400

sooty2055 said:
My 19 plate 2.0 awd is a sealed box ,so worth checking as Ford would have to fix it .

Enjoy that delusion while it lasts. Ford will do nothing in support of a six year old gearbox

davidjohn · 2025-09-29T16:28:44-0400

smartguy69 said:
The "frighteners" for many is reality. Here's another one. Failure of the early powershift in not internet nonsense at all. I lost count now of the number of failures on here.

https://www.kugaownersclub.co.uk/threads/new-member-and-ford-kuga-2013-automatic.34121/?post_id=357564#post-357564

I have had folks tell me they would not touch a diesel Kuga even if it was given to them for free ,all because of what they have seen on the internet If I had took any notice of it I would not have my Kuga ,things break and things can be repaired if my gearbox started to give trouble it would be repaired, Likewise if I had powershift gearbox it would be repaired ,and probably uprated at the same time. I would not think it was the end of the world ,thats it,

NigelB · 2025-09-29T16:39:45-0400

Sadly, you are wrong and such 'absolutes' ignore harsh economic reality. The plastic gearbox debacle affects 10-12 year old vehicles worth, with a following wind £5-7000. If you are seriously suggesting that anyone should spend c£5000 on a gearbox rebuild (that is the cost of doing the rebuild with a degree of care) then I can only express,shall we call it, surprise.

NigelB · 2025-09-29T16:43:28-0400

Just to add, that the original gearbox cannot be uprated ( it can be replaced of course) save for a single example where the work was undertaken by a mechanic with almost genius level engineering skills . No official channel would touch it

davidjohn · 2025-09-29T16:56:40-0400

NigelB said:
Sadly, you are wrong and such 'absolutes' ignore harsh economic reality. The plastic gearbox debacle affects 10-12 year old vehicles worth, with a following wind £5-7000. If you are seriously suggesting that anyone should spend c£5000 on a gearbox rebuild (that is the cost of doing the rebuild with a degree of care) then I can only express,shall we call it, surprise.

I actually know a forum member with a powershift gearbox, He told me he has done over 65,000 a lot it towing a caravan '
He does know he is on borrowed time before it starts giving trouble ,And has looked at a replacement car and soon realised there is nothing on the market as good as his Kuga , He has already been quoted £4000 for an uprated guaranteed for life replacement, Which he said he would gladly pay in order to keep his Kuga, I could quote the members name but do not think it would be ethical to do that.

NigelB · 2025-09-29T17:52:27-0400

£4000, from experience, is remarkably cheap.

smartguy69 · 2025-09-29T17:53:24-0400

davidjohn said:
I actually know a forum member with a powershift gearbox, He told me he has done over 65,000 a lot it towing a caravan '
He does know he is on borrowed time before it starts giving trouble ,And has looked at a replacement car and soon realised there is nothing on the market as good as his Kuga , He has already been quoted £4000 for an uprated guaranteed for life replacement, Which he said he would gladly pay in order to keep his Kuga, I could quote the members name but do not think it would be ethical to do that.

What plate his is car i.e. 64 plate, 15 plate, newer, older.

Ozekuga · 2025-09-29T18:44:55-0400

Maybe the forum member would like to reveal who they are.
I'm sure armed with the knowledge that they know a place who can make the older type powershift gearbox bullit proof they would get many followers on this forum.

KevKing · 2025-09-30T02:07:59-0400

Please let me know, I have found a specialist in Rayleigh, Essex but transporting the car will cost £800 plus around £3500 for a rebuild with guarantee. My gearbox has gone for a second time, and Ford France want 8000 euros to fix it after a simple diagnostic where they didn't even fully analyse the results! Well not fix it as they are so incompetent they can't, they just replace it with a new one. My options (I do like the car) are to get the box rebuilt and then sell it in part exchange at a dealer or just sell it for bits which is a shame. Anyone with any other advice (or the best course of action) please please let me know! Thanks

davidjohn · 2025-09-30T03:00:56-0400

NigelB said:
Just to add, that the original gearbox cannot be uprated ( it can be replaced of course) save for a single example where the work was undertaken by a mechanic with almost genius level engineering skills . No official channel would touch it

I myself do not feel competent to under take an auto gearbox repair, but for those who do feel competent there are uprated repair kits available with metal uprated spring retainers replacing the plastic problematic retainers which are the root of most powershift problems. From what I have seen the cost of metal repair kits looks very reasonable at about £150, sounds like a bargain for those who are up to it. Anyone with any doubts why not do your own search.

NigelB · 2025-09-30T04:10:20-0400

KevKing said:
Please let me know, I have found a specialist in Rayleigh, Essex but transporting the car will cost £800 plus around £3500 for a rebuild with guarantee. My gearbox has gone for a second time, and Ford France want 8000 euros to fix it after a simple diagnostic where they didn't even fully analyse the results! Well not fix it as they are so incompetent they can't, they just replace it with a new one. My options (I do like the car) are to get the box rebuilt and then sell it in part exchange at a dealer or just sell it for bits which is a shame. Anyone with any other advice (or the best course of action) please please let me know! Thanks

davidjohn said:
I myself do not feel competent to under take an auto gearbox repair, but for those who do feel competent there are uprated repair kits available with metal uprated spring retainers replacing the plastic problematic retainers which are the root of most powershift problems. From what I have seen the cost of metal repair kits looks very reasonable at about £150, sounds like a bargain for those who are up to it. Anyone with any doubts why not do your own search.

Strange then that no one appears to have done it among all the members of this forum, including those who have advanced engineering and mechanical skills. I believed that the issue was the clogging of the galleries from the detritus when the plastic elements broke down rendering the gearbox totally irreparable.

Terrier50 · 2025-09-30T05:29:39-0400

NigelB said:
Two words. Get Rid.

are there any early warning signs, or does it just conk out ?

NigelB · 2025-09-30T05:38:06-0400

My understanding is that over revving is an early sign but if one of the plastic guides lets go and breaks up there is no warning as such

Terrier50 · 2025-09-30T06:06:57-0400

NigelB said:
My understanding is that over revving is an early sign but if one of the plastic guides lets go and breaks up there is no warning as such

ok thanks...had mine almost 8 years and it's been great, but was already thinking time to change in 2026. Do we know how prevalent this issue is, like what % of affected models are now conking out...will a garage take mine in p/x for example?

Mark 2.5 Kuga and Powershift

keithmac

Dupont

sooty2055

smartguy69

Terrier50

NigelB

NigelB

davidjohn

NigelB

NigelB

davidjohn

NigelB

smartguy69

Ozekuga

KevKing

davidjohn

NigelB

Terrier50

NigelB

Terrier50

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