[keithmac]

Looks good, just be careful fitting it.

I normally smear a bit of rubber grease on before fitting seals.

Hope it all goes well.

 

[teemurama]

Thx! Btw, did you installed seal with normal screwdriver as general in Youtube-videos ?

 

[teemurama]

I got all parts for gearbox today. New plastic clips looked quite good. It was funny to notice after replacing springs and clips that spring setup is much more stiffer than earlier. See video.

But then came hardest part, to get clutch cover locked with iron rim. First I couldn't get it back. It's very hard to install when you need to put it back as it is is gearbox on table. I gave up and took whole clutch out of box. I got it installed when clutch was on table. But then I couldn't get locking ring to right thread. I took clutch open again and put it back to gearbox part by part. Don't know if it helped but after that I got rim back. Seal cover was quite easy to install. I tighten holding clips little and then pushed seal carefully on.

Find out that there was 3 clips broken. One spring was snapped and fourth clip almost broken. So I think it was time to repair those. Hopefully I installed everything back as it should.
Flange is still wobbling a little but I think it's because plastic clips on clutch cover are little loose. I saw somewhere repair kit for those also but I don't know how those can be fixed ( can't find any video for that ) . But I'm not doing anything more at his time. I think it will last few years with this repair, hopefully.

 

[keithmac]

how did it go in the end?. The springs and guides were well past their best.

I`m amazed these don`t make more noise at that point, mine had a very feint rattle but was absolutely shot when I took it to bits.

 

[teemurama]

how did it go in the end?. The springs and guides were well past their best.

I`m amazed these don`t make more noise at that point, mine had a very feint rattle but was absolutely shot when I took it to bits.

Rest of assembly was quite easy. At first try I couldn't get gearbox back to engine but noticed that box was little wrong angle. I change position little and after that it slipped correct place. So no need for special tool in installation. I just measured clutch position it with normal measuring tape.

I have feeling that gear change is little smoother nowadays. And specially when I'm changing from P to D it's smoothier than earlier. I still have tiny oil leak and now I'm not sure where its coming. It's possible that clutch cover is leaking a bit ( because I hadn't tool for that even I tried to be very gently ) or then it's still small leak in rear crank seal. It's quite small so I'm not worried about that one. I need to check gearbox oil level after e.g. 10000km so I can confirm that its not gearbox oil. Or if it's I need to add extra oil some point. Very interesting to see how long car and specially gearbox lasts
Thank you for all your help!!!

 

[gotj]

1) The last automatic kuga I bought had a leak, and it was the gearbox that had been overfilled. Do you know, and have you followed the proper (and weird) refill procedure?
2) With the gearbox out of the car, there's no better time to replace the transmission end crankshaft seal. Haven't you done it?

 

[teemurama]

1) The last automatic kuga I bought had a leak, and it was the gearbox that had been overfilled. Do you know, and have you followed the proper (and weird) refill procedure?
2) With the gearbox out of the car, there's no better time to replace the transmission end crankshaft seal. Haven't you done it?

1) Its possible that it came little too overfilled because I forgot to heat up gearbox. Where oil is getting out ??
2) Yes, that was original reason why I took gearbox off from car.

 

[keithmac]

Ford don't give a temperature to do the oil level check, as long as you've done the correct oil level procedure you should be fine.

 

[gotj]

1) Its possible that it came little too overfilled because I forgot to heat up gearbox. Where oil is getting out ??
2) Yes, that was original reason why I took gearbox off from car.

In my car the oil was leaking from the seal in the gearbox, it was leaking gearbox oil. Not the crankshaft seal, that would have been engine oil. The previous owner must have thought, more is better.

 

[PankG]

The only one that will fit is from a Mk2 163ps 2013 or early 2014 NOT a 2014 180bhp (it's completely different).

You would be best off having your own box refurbished by a reputable specialist imho.

London Automatic Transmissions do hundreds of these gearboxes.

A pre 2013 box may fit, I wouldn't chance it personally.

The TCU (gearbox brain) is inside the gearbox, a second hand one may require coding to your car, firmware flashing.

The gearbox you have is prone to a few failures, I wouldn't entertain a 2nd hand unit.

Just an updates guys, Managed to get the gearbox refurbished by London Automatic Transmission and they did a great job.

 

[smartguy69]

It's always nice to get an update. Thanks for posting @PankG .

 

[Fred Karno]

Hi Keith,

I have been following the discussions on the forum concerning reliability of the Powershift gearbox fitted to the Ford Kuga, and it appears that you are something of an expert on the issue. (I don't envy you for the trials you've had gaining this knowledge - your patience and tenacity does you great credit!)

I have a Kuga ST Line X TDCi 4x4 fitted with a Powershift gearbox. The car was registered on 19 January 2018 and was (probably) manufactured in 2017. I believe Ford have revised the gearbox in cars built from 2017 onwards to resolve the problems caused by the plastic spacers - is this correct?

As you have suggested on another thread, I checked my gearbox labelling and found the following:

Label on the box - FV4R 7000 AG
AWBA1 260917 132052

Raised details - DS7R 7F097
AISI 90Cu9(Fe)
Can you advise whether my gearbox is of the updated type (if there is one) or do I have a problematic one?

Thanks for any light you can shed on this. I will be speaking to my local Ford dealer next week to confirm the car's build date and to see what they have to say about the gearbox. If I discover anything new I'll let you know.

Kind regards and Happy New Year to all - lets hope It's better than last year!

 

[NigelB]

A Happy New Year to you as well.

I will await Keith's answer but IIRC everything from 2017 on has the later (modified not to be built of Airfix spares) box.

 

[keithmac]

Hi Keith,

I have been following the discussions on the forum concerning reliability of the Powershift gearbox fitted to the Ford Kuga, and it appears that you are something of an expert on the issue. (I don't envy you for the trials you've had gaining this knowledge - your patience and tenacity does you great credit!)

I have a Kuga ST Line X TDCi 4x4 fitted with a Powershift gearbox. The car was registered on 19 January 2018 and was (probably) manufactured in 2017. I believe Ford have revised the gearbox in cars built from 2017 onwards to resolve the problems caused by the plastic spacers - is this correct?

As you have suggested on another thread, I checked my gearbox labelling and found the following:

Label on the box - FV4R 7000 AG
AWBA1 260917 132052

Raised details - DS7R 7F097
AISI 90Cu9(Fe)
Can you advise whether my gearbox is of the updated type (if there is one) or do I have a problematic one?

Thanks for any light you can shed on this. I will be speaking to my local Ford dealer next week to confirm the car's build date and to see what they have to say about the gearbox. If I discover anything new I'll let you know.

Kind regards and Happy New Year to all - lets hope It's better than last year!

Hello Fred, you definitely have the better gearbox in your car.

It still requires proper servicing (make sure it gets done as Ford seem to think it's an extra..)

Earlier cars were 37,500 miles or 3 years for gearbox service, later ones may have extended it to 4 years.

Personal I'd be doing it every 30,000 miles.

Happy New Year!.

 

[Fred Karno]

Hello Fred, you definitely have the better gearbox in your car.

It still requires proper servicing (make sure it gets done as Ford seem to think it's an extra..)

Earlier cars were 37,500 miles or 3 years for gearbox service, later ones may have extended it to 4 years.

Personal I'd be doing it every 30,000 miles.

Happy New Year!.

Hello Fred, you definitely have the better gearbox in your car.

It still requires proper servicing (make sure it gets done as Ford seem to think it's an extra..)

Earlier cars were 37,500 miles or 3 years for gearbox service, later ones may have extended it to 4 years.

Personal I'd be doing it every 30,000 miles.

Happy New Year!.

Nigel / Keith,

Thanks for the responses - they've put my mind at rest! The photos and videos of plastic debris falling out of autobox clutches put me off my Christmas pudding! "Airfix" sums it up perfectly.

I had the gearbox serviced last year at around 27,000 miles when the car was 3.5 years old. I thought I was being over cautious but now I'm glad I got it done.

Kind regards

 

[teemurama]

Hi!

I changed year ago plastic clips and springs to clutch. Now car ( gearbox ?) started to keep knocking noise even gear is in P-mode in idle. It can be heard also when driving slowly. Its not keeping that all the time but sometimes, maybe 1 time in 10 or 15 seconds. Its just like someone would hit with hammer to motor cover. What could be the reason ? I have been driving about 20000km's and everything have been good.

 

[Nforcer]

Hello Keith, first of all thanks for all the info, i personally consider you the powershift guru, i have a question, i got mondeo mk4 2012 with powershift,on the gearbox it is stated remanufactured in UK on 2017, is it the new version of dct450 or still old one? Service confirmed the gearbox was changed..

 

[smartguy69]

Hello Keith, first of all thanks for all the info, i personally consider you the powershift guru, i have a question, i got mondeo mk4 2012 with powershift,on the gearbox it is stated remanufactured in UK on 2017, is it the new version of dct450 or still old one? Service confirmed the gearbox was changed..

If you want a particular member to receive an alert for when you mention them you need to put the @ symbol in front of their name like this below.

@keithmac - your assistance is required for the above post. I know it's reference to a Mondeo.

 

[Nforcer]

@smartguy69 i apologize, thanks for the assistance!

 

[davidoff]

@smartguy69 i apologize, thanks for the assistance!

We consider him the power shift guru as well, other gurus are available 👍