Section 1533 (Automatic Transmission - 6-Speed POWERSHIFT Transmission - DPS6 6DCT250): Disassembly: Transmission
WARNING: This page is about a different car, the 2018 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 307-580 Holding Fixture TKIT-2006UF-FLM TKIT-2006UF-ROW |
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| 307-670 Remover/Installer, Shift Lever Seal TKIT-2010D-FLM TKIT-2010D-ROW |
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| 307-673 Remover, Outer Input Shaft Seal TKIT-2010D-FLM TKIT-2010D-ROW |
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| 307-675 Fixture, Clutch Remover/Installer TKIT-2010D-FLM TKIT-2010D-ROW |
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| 307-680 Table, Assembly (DPS6) TKIT-2010D-FLM TKIT-2010D-ROW |
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| Feeler Gauge | |
| Flat Headed Screw Driver | |
| Punch | |
| Locking Pliers |
- Refer to the Disassembly video.multimedia:A supplement to the article is available.
- Remove the transmission wiring harness.
- Remove the following items:
- Remove the TCM. Refer to: Transmission Control Module (TCM) .
- Remove the TR sensor. Refer to: Transmission Range (TR) Sensor .
- Remove the OSS sensor. Refer to: Output Shaft Speed (OSS) Sensor .
- Remove the ISS sensor. Refer to: Input Shaft Speed (ISS) Sensor .
- Remove the clutch actuator. Refer to: Clutch Actuator .
- Using the special tools, remove and discard the hollow input shaft seal. Install Special Service Tool: 307-673 Remover, Outer Input Shaft Seal.
- Remove the bolts and the guide tube.
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NOTE: Take extra care not to damage the bearing.
Using a punch, pierce the input shaft seal. Use the General Equipment: Punch
- Thread a 2.5 x 15 mm self tapping screw into the input shaft seal and remove the seal with a pair locking pliers. Use the General Equipment: Flat Headed Screw Driver. Use the General Equipment: Locking Pliers
- Remove and discard the input shaft snap ring.
- Using a punch, remove the clutch housing plug. Use the General Equipment: Punch
- Remove and discard the manual lever bolt and remove the manual lever.
- Install the special tool on the shift lever seal. Apply pressure to the top of the special tool while threading it into the seal. Use Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal.
- Using the special tool, remove the shift lever seal. Use Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal.
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NOTE: Fastener quantity varies by application.
Remove the transmission case bolts.
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NOTE: Fastener quantity varies by application.
Remove the transmission case bolts.
- Install the special tool on the input shaft. Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
- Install the special tool and compress the input shaft. Turn the threaded bar 20 turns after it makes contact with the input shaft. Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
Torque: 159 lb.in (18 Nm)
- Remove the clutch housing from the transmission case.
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NOTE: Anytime the transmission case is separated the input shaft bearing must be replaced.
Remove the bolts, the bearing retainer and the bearing. Discard the bolts and the bearing.
- Remove the park plunger plug.
- Using a brass punch, gently tap the park plunger from the outside to the inside to remove it from the clutch housing. Use the General Equipment: Punch
- Remove the park pawl actuator shaft assembly.
- Remove the park pawl.
- Remove the large clock gears.
- Remove the small clock gears.
- Remove the differential.
- Remove the magnet.
- Install the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
- Install the special tool. Remove Special Service Tool: 307-580 Holding Fixture.
- Remove and discard the output shaft bearing retainer bolts.
- Remove the transmission case.
- Remove the LH halfshaft seal.
- Remove the RH halfshaft seal.
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NOTE: This step only applies to transmissions built before April-2013.
Remove the oil spout.
- Remove the shift fork rods.
- Remove the shift drums.
- Remove the shift forks.
- Install the special tools. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
- Remove the input and output shaft assemblies from the special tool. Remove Special Service Tool: 307-680 Table, Assembly (DPS6).
- Remove the output shaft assembly. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
- Remove the input shaft assembly. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
- Remove the output shaft assembly. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
- Remove the hollow input shaft from the inner input shaft.
- Clean and inspect all components for wear or damage.
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NOTE: If the clearance is more than the maximum measurement stated in Specifications or the shift fork or the adjacent synchronizer ring has signs of wear or damage, both the shift fork and the synchronizer assembly must be replaced.
Using a feeler gauge, measure the clearance between the fork and hub in various places around the circumference. Refer to: 1st-5th Gear Synchronizer . Refer to: 2nd-6th Gear Synchronizer . Refer to: 3rd Gear Synchronizer . Refer to: 4th-Reverse Gear Synchronizer . Use the General Equipment: Feeler Gauge
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NOTE: Apply pressure on the synchronizer ring while taking the measurements.NOTE: If the clearance is less than the minimum measurement stated in Specifications , install a new friction ring and synchronizer assembly.
Using a feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference. Refer to: 1st-5th Gear Synchronizer . Refer to: 2nd-6th Gear Synchronizer . Refer to: 3rd Gear Synchronizer . Refer to: 4th-Reverse Gear Synchronizer . Use the General Equipment: Feeler Gauge