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Automatic Dual Clutch Transaxle (Dct) Powershift (DPS6/6DCT250): Overview Ford Focus III

Automatic Trans ~1519 words

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

Normal Operation and Fault Conditions

Clutch motor 1 is a 3 phase bi-directional DC motor that is controlled by the TCM. The TCM monitors the clutch motor position using three Hall-effect sensor inputs.

DTCDescriptionFault Trigger Conditions
P0805Clutch Position Sensor "A" CircuitClutch motor A fault detected.
P0806Clutch Position Sensor "A" Circuit Range/PerformanceClutch motor A hall effect sensor fault detected.
P0809Clutch Position Sensor "A" Circuit IntermittentClutch motor A sequence fault detected.
P0900Clutch "A" Actuator Control Circuit/OpenOpen circuit detected on one of the 3 phase circuits.
P0901Clutch "A" Actuator Control Circuit Range/PerformanceThis DTC sets along with P0900, P0902 and/or P0903. Used to turn on the wrench light.
P0902Clutch "A" Actuator Control Circuit LowShort to ground detected on one of the 3 phase circuits.
P0903Clutch "A" Actuator Control Circuit HighShort to power detected on one of the 3 phase circuits.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

Clutch motor 2 is a 3 phase bi-directional DC motor that is controlled by the TCM. The TCM monitors the clutch motor position using three Hall-effect sensor inputs.

DTCDescriptionFault Trigger Conditions
P087AClutch Position Sensor "B" CircuitClutch motor B fault detected.
P087BClutch Position Sensor "B" Circuit Range/PerformanceClutch motor B hall effect sensor fault detected.
P087EClutch Position Sensor "B" Circuit IntermittentClutch motor B sequence fault detected.
P090AClutch "B" Actuator Control Circuit/OpenOpen circuit detected on one of the 3 phase circuits.
P090BClutch "B" Actuator Control Circuit PerformanceThis DTC sets along with P090A, P090C and/or P090D. Used to turn on the wrench light.
P090CClutch "B" Actuator Control Circuit LowShort to ground detected on one of the 3 phase circuits.
P090DClutch "B" Actuator Control Circuit HighShort to power detected on one of the 3 phase circuits.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

The OSS sensor is a magnetic pickup and measures the input speed of the output shaft and sends this signal to the TCM. The OSS sensor is used for TCC scheduling and shift time. The rotation direction is not measured. The OSS sensor is located in the transmission housing above the rotor in the differential. If DTC P1934 or P193F are set along with OSS sensor DTC, follow the OSS sensor diagnostic routines. If DTC U0402 sets along with P1934 then the TCM is reporting invalid data to the PCM.

DTCDescriptionFault Trigger Conditions
P0720Output Shaft Speed Sensor CircuitOSS sensor fault detected.
P0721Output Shaft Speed Sensor Circuit Range/PerformanceErratic OSS sensor signal - noisy signal, out of range high, or not plausible. Detection of this fault is disabled if a power supply P06A8 or circuit fault P0720 is present.
P0722Output Shaft Speed Sensor Circuit No SignalOSS sensor failed to 0 speed when the ABS wheel speed sensors indicate vehicle speed. Detection of this fault is disabled if a power supply P06A8 or circuit fault P0720 is present.
P0723Output Shaft Speed Sensor Circuit IntermittentThis DTC sets along with P0720, P0721 and/or P0722. Used to turn on the wrench light.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

ISS sensor 1 measures the input speed and the rotating direction of input shaft 1. The input shaft can be stationary. Therefore, it is necessary the sensor system detect the stationary state of the input shaft accurately. By being stationary the sensor must not indicate speed unequal to 0 (also not, if the motor runs by high speeds). The slow rolling of the car has to be detected safely. ISS sensor 2 measures the input speed of input shaft 2. The rotation direction is not measured.

DTCDescriptionFault Trigger Conditions
P06A6Sensor Reference Voltage "A" Circuit Range/PerformanceISS sensor 1 power supply circuit failure.
P0715Turbine/Input Shaft Speed Sensor "A" CircuitISS sensor 1 circuit failure detected.
P06A7Sensor Reference Voltage "B" Circuit Range/PerformanceISS sensor 2 power supply circuit failure.
P0716Turbine/Input Shaft Speed Sensor "A" Circuit Range/PerformanceErratic ISS sensor 1 signal - noisy signal, out of range high, or not plausible. Detection of this fault is disabled if a power supply P06A6 or circuit fault P0715 is present.
P0717Turbine/Input Shaft Speed Sensor "A" Circuit No SignalISS sensor 1 failed to 0 speed when vehicle conditions indicated the input shaft speed should be non-zero. Detection of this fault is disabled if a power supply P06A6 or circuit fault P0715 is present.
P0718Turbine/Input Shaft Speed Sensor "A" Circuit IntermittentThis DTC sets along with P06A6, P0715, P0716 and/or P0717. Used to turn on the wrench light.
P2765Input/Turbine Speed Sensor "B" CircuitISS sensor 2 circuit failure detected.
P2766Input/Turbine Speed Sensor "B" Circuit Range/PerformanceErratic ISS sensor 1 signal - noisy signal, out of range high, or not plausible. Detection of this fault is disabled if a power supply P06A7 or circuit fault P2765 is present.
P2767Input/Turbine Speed Sensor "B" Circuit No SignalISS sensor 1 failed to 0 speed when vehicle conditions indicated the input shaft speed should be non-zero. Detection of this fault is disabled if a power supply P06A7 or circuit fault P2765 is present.
P2768Input/Turbine Speed Sensor "B" Circuit IntermittentThis DTC sets along with P06A7, P2765, P2766 and/or P2767. Used to turn on the wrench light.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

The TR sensor monitors the position of the manual control lever shaft. The TR sensor is mounted on the transmission. The TR sensor allows the vehicle to start in PARK and NEUTRAL. The TR sensor output signal is linear over the measurement range and the TCM receives this signal verifying the selector lever position.

The TR sensor inputs are used for selector lever position starter inhibit relay reversing lamps.

DTCDescriptionFault Trigger Conditions
P0706Transmission Range Sensor A Circuit Range/PerformanceTR sensor A frequency out of range (200-300 Hz). DTC does not set for circuits that are open, shorted to ground or shorted to power.
P0707Transmission Range Sensor A Circuit LowTR sensor A duty cycle out of range low, below park minimum duty cycle.
P0708Transmission Range Sensor A Circuit HighTR sensor A duty cycle out of range high, below low maximum duty cycle.
P0709Transmission Range Sensor A Circuit IntermittentTR sensor intermittent park or neutral signal during pre-crank test.
P2801Transmission Range Sensor B Circuit Range/PerformanceTR sensor B frequency out of range (200-300 Hz). DTC does not set for circuits that are open, shorted to ground or shorted to power.
P2802Transmission Range Sensor B Circuit LowTR sensor B duty cycle out of range low, below low minimum duty cycle.
P2803Transmission Range Sensor B Circuit HighTR sensor B duty cycle out of range high, below park maximum duty cycle.
P2804Transmission Range Sensor B Circuit IntermittentThis DTC sets with P2801, P2802 and/or P2803. Used to light the wrench light.
P2805Transmission Range Sensor A / B CorrelationTR sensor A and B sum must be 100 +/- 2x sensor tolerance. If both sensors are in-range and no other Diagnostic Trouble Codes (DTCs) are set, but the sum fails to add up to 100%, this DTC will set.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

The shift system consists of two independent sub-systems controlling the transmission synchronizer pre-selections and engagements. This arrangement provides independent control of the two transmission and a mechanical interlock that prevents two gears within the same transmission from being engaged simultaneously. The TCM contains two electric motors that mesh with and drive the first double gear wheel, which drives the second double gear which finally drives the shift drum. Gearing between the shift motors and the drums reduce speed and multiply torque. Position sensors in the TCM detect motor position. Shift drum position is learned by the TCM during a teach-in process that involves rotating each drum.

DTCDescriptionFault Trigger Conditions
P2831Shift Fork "A" Position CircuitShift drum motor 1 fault detected.
P2832Shift Fork "A" Position Circuit Range/PerformanceTCM found an error with shift drum 1 that indicated it has lost position.
P2835Shift Fork "A" Position Circuit IntermittentShift drum motor 1 sequence fault detected.
P2836Shift Fork "B" Position CircuitShift drum motor 2 fault detected.
P2837Shift Fork "B" Position Circuit Range/PerformanceTCM found an error with shift drum 2 that indicated it has lost position.
P283AShift Fork "B" Position Circuit IntermittentShift drum motor 2 sequence fault detected.
P285BShift Fork "A" Actuator Circuit / OpenShift drum motor 1 open circuit fault detected.
P285CShift Fork "A" Actuator Circuit PerformanceThis DTC sets with P285B, P285D and/or P285E. Used to light the wrench lamp.
P285DShift Fork "A" Actuator Circuit LowShift drum motor 1 short to ground fault detected.
P285EShift Fork "A" Actuator Circuit HighShift drum motor 1 short to power fault detected.
P285FShift Fork "B" Actuator Circuit / OpenShift drum motor 2 open circuit fault detected.
P2860Shift Fork "B" Actuator Circuit PerformanceThis DTC sets with P285F, P2861 and/or P2862. Used to light the wrench lamp.
P2861Shift Fork "B" Actuator Circuit LowShift drum motor 2 short to ground fault detected.
P2862Shift Fork "B" Actuator Circuit HighShift drum motor 2 short to power fault detected.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

There are two electric motors used to shift the gears in the transmission, one for gears 1-3-5 and one for gears R-2-4-6. The gear shifting is made by two shift drums connected to shift motor pinion via two ideal gears. The maximum shift force is 1500N (337 lb). The motors are integrated in the TCM and work independently of each other.

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to TRANSMISSION CONTROL for schematic and connector information.

The BJB provides battery and ignition voltage to the TCM. If the system voltage is too low, too high or out of range during the self-test, the following Diagnostic Trouble Codes (DTCs) may set.

DTCDescriptionFault Trigger Conditions
P0702Transmission Control System ElectricalThis DTC sets along with P0882 and P0883.
P0882TCM Power Input Signal LowTCM battery voltage is less than 9 volts.
P0883TCM Power Input Signal HighTCM battery voltage is greater than 18 volts.
P1397System Voltage Out Of Self-Test RangeSystem voltage outside of the self-test range during the KOEO or KOER self-test.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to MODULE COMMUNICATION NETWORK for schematic and connector information.

When a network message is suspected as missing or confirmed by a missing message DTC (U-code), its important to look for other conditions that may also be present in additional modules throughout the vehicle. Once a DTC sets in the TCM, it may be helpful to review the complete message list available in the ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (EXCEPT DIESEL & HYBRID) and see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also set in those modules. Confirmation of missing messages common to multiple modules may indicate the originating module is the source of the concern or the communication network may be experiencing some problems.

DTCDescriptionFault Trigger Conditions
U0100Lost Communication With ECM/PCM "A"Lost communication with the PCM but the TCM is receiving messages from other modules.
U0115Lost Communication With ECM/PCM "B"Lost communication with the PCM but the TCM is receiving messages from other modules.
U0294Lost Communication With Powertrain Control Monitor ModuleLost communication with the PCM but the TCM is receiving messages from other modules.
U0401Invalid Data Received from ECM/PCM AReceiving CAN messages from the PCM but the PCM is indicating failures of certain key signals.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to MODULE COMMUNICATION NETWORK for schematic and connector information.

When a network message is suspected as missing or confirmed by a missing message DTC (U-code), its important to look for other conditions that may also be present in additional modules throughout the vehicle. Once a DTC sets in the TCM, it may be helpful to review the complete message list available in the ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (EXCEPT DIESEL & HYBRID) and see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems.

DTCDescriptionFault Trigger Conditions
U0121Lost Communication With Anti-Lock Brake System (ABS) Control ModuleLost communication with ABS module but the TCM is receiving messages from other modules.
U0129Lost Communication With Brake System Control ModuleLost communication with ABS module but the TCM is receiving messages from other modules.
U0415Invalid Data Received From Anti-Lock Brake System (ABS) Control ModuleReceiving CAN messages from the ABS but the ABS is indicating failures of certain key signals.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to MODULE COMMUNICATION NETWORK forr schematic and connector information.

When a network message is suspected as missing or confirmed by a missing message DTC (U-code), its important to look for other conditions that may also be present in additional modules throughout the vehicle. Once a DTC sets in the TCM, it may be helpful to review the complete message list available in the ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (EXCEPT DIESEL & HYBRID) and see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems.

DTCDescriptionFault Trigger Conditions
U0140Lost Communication With Body Control Module Control ModuleCurrently the calibration is not available.
U0141Lost Communication With Body Control Module Control Module "A"Currently the calibration is not available.

DTC FAULT TRIGGER CONDITIONS

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

REFER to: DIAGNOSTIC METHODS .

Refer to MODULE COMMUNICATION NETWORK for schematic and connector information.

When a network message is suspected as missing or confirmed by a missing message DTC (U-code), its important to look for other conditions that may also be present in additional modules throughout the vehicle. Once a DTC sets in the TCM, it may be helpful to review the complete message list available in the ENGINE CONTROLS - POWERTRAIN DTC CHARTS & DESCRIPTIONS (EXCEPT DIESEL & HYBRID) and see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems.

DTCDescriptionFault Trigger Conditions
U0155Lost Communication With Instrument Panel Cluster (IPC) Control ModuleLost communication with IPC module.

DTC FAULT TRIGGER CONDITIONS

Diagnostic Parameter Identification (PID) Chart

Note. The following general PID list may be of use to the technician when exercising output state control

PIDsPID Description
1stBLCK_GR_JMP1st Gear Is Blocked Due To Gear Jump Occurred
1stBLOCK_TMP1st Gear Is Blocked Temporarily Protect Mode
2ndBLCK_GR_JMP2nd Gear Is Blocked Due To Gear Jump Occurred
2ndBLOCK_TMP2nd Gear Is Blocked Temporarily Protect Mode
3rdBLCK_GR_JMP3rd Gear Is Blocked Due To Gear Jump Occurred
3rdBLOCK_TMP3rd Gear Is Blocked Temporarily Protect Mode
4thBLCK_GR_JMP4th Gear Is Blocked Due To Gear Jump Occurred
4thBLOCK_TMP4th Gear Is Blocked Temporarily Protect Mode
5thBLCK_GR_JMP5th Gear Is Blocked Due To Gear Jump Occurred
5thBLOCK_TMP5th Gear Is Blocked Temporarily Protect Mode
6thBLCK_GR_JMP6th Gear Is Blocked Due To Gear Jump Occurred
6thBLOCK_TMP6th Gear Is Blocked Temporarily Protect Mode
CLTC_A_BLCKClutch A Actuator Blocked (1)
CLTC_A_CLOS_FClutch A Reference Position Closed Failed
CLTC_A_CUR_MESClutch A Actuator Current - Measured
CLTC_A_F_MANAGClutch A Failure Management Status
CLTC_A_LOWCONFClutch A Low Confidence In Sensed Position
CLTC_A_MTR_DSDClutch A Actuator Motor - Desired
CLTC_A_OPEN_FClutch A Reference Position Open Direction Failed
CLTC_A_POS_FClutch Motor A - Position Sensor Fault
CLTC_A_SEQ_FClutch Motor A - Phase Sequence Fault
CLTC_A_SLFDIAGClutch A Self Diagnostic Procedure Status
CLTC_A_SLIPMESClutch A Measured Slip
CLTC_A_SPRNGClutch A Spring Cannot Fully Open Clutch
CLTC_B_BLCKClutch B Actuator Blocked (2)
CLTC_B_CLOSE_FClutch B Reference Position Closed Failed
CLTC_B_CUR_MESClutch B Actuator Current - Measured
CLTC_B_F_MANAGClutch B Failure Management Status
CLTC_B_LOWCONFClutch B Low Confidence In Sensed Position
CLTC_B_MTR_DSDClutch B Actuator Motor - Desired
CLTC_B_OPEN_FClutch B Reference Position Open Direction Failed
CLTC_B_POS_FClutch Motor B - Position Sensor Fault
CLTC_B_SEQ_FClutch Motor B - Phase Sequence Fault
CLTC_B_SLFDIAGClutch B Self Diagnostic Procedure Status
CLTC_B_SLIPMESClutch B Measured Slip
CLTC_B_SPRNGClutch B Spring Cannot Fully Open Clutch
CLTC_MTR_A_FClutch Motor A - Phase Circuit Fault
CLTC_MTR_B_FClutch Motor B - Phase Circuit Fault
CLUTCH_A_OPENClutch A Is Completely Open - Measured
CLUTCH_B_OPENClutch B Is Completely Open - Measured
FOOT_BRAKEFoot Brake - Foot brake state used by strategy
GEAR_CMDGear Commanded
GEAR_ENGAGEDTransmission Gear Engaged
GEAR_OSCGear Command by Output State Control
GEARBX_SF_A_FGearbox Error Status for Shift Fork A
GEARBX_SF_B_FGearbox Error Status for Shift Fork B
ISS_A_PC_FInput Shaft Speed Sensor A - Power/Circuit Fault
ISS_A_RAWInput Shaft Speed A - Raw
ISS_B_PC_FInput Shaft Speed Sensor B - Power/Circuit Fault
ISS_B_RAWInput Shaft Speed B - Raw
ISS_EFFECT_RPMEffective Input Shaft Speed
OSS_PC_FOutput Shaft Speed Sensor - Power or Circuit Fault
OSS_SRCUnfiltered Output Shaft Speed A
REVBLCK_GR_JMPReverse Gear Is Blocked Due To Gear Jump Occurred
REVBLOCK_TMPReverse Is Blocked Temporarily Protect Mode
RLCReverse Lamp Control
RLC_FReverse Control Lamp Status
SF_A_CURR_MESShift Fork A Actuator Current - Measured
SF_A_ENGAG_STAShift Fork A Engagement Control Status
SF_A_GRRAT_MESShift Fork A Gear Ratio - Measured
SF_A_POS_MESShift Fork A Actuator Position - Measured
SF_A_POS_STATPosition Signal Status for Shift Fork A Actuator
SF_A_POS_TARGShift Fork A Actuator Position - Target
SF_A_ROTAT_MESShift Fork A Rotational Position - Measured
SF_B_CURR_MESShift Fork B Actuator Current - Measured
SF_B_ENGAG_STAShift Fork B Engagement Control Status
SF_B_GRRAT_MESShift Fork B Gear Ratio - Measured
SF_B_POS_MESShift Fork B Actuator Position - Measured
SF_B_POS_STATPosition Signal Status for Shift Fork B Actuator
SF_B_POS_TARGShift Fork B Actuator Position - Target
SF_B_ROTAT_MESShift Fork B Rotational Position - Measured
SHFRK_A_CAL_E1Self Calibration Error - Shift Fork A Movement
SHFRK_A_CAL_E2Self Calibration Error - Shift Fork A Reference
SHFRK_B_CAL_E1Self Calibration Error - Shift Fork B Movement
SHFRK_B_CAL_E2Self Calibration Error - Shift Fork B Reference
SHFRK_NO_CAL_0Self Calibration Prevented - Brake Input Status
SHFRK_NO_CAL_1Self Calibration Prevented - Clutch A is Not Open
SHFRK_NO_CAL_2Self Calibration Prevented - Clutch B is Not Open
SHFRK_NO_CAL_3Self Calibration Prevented - Output Shaft Speed
SHFRK_NO_CAL_4Self Calibration Prevented - Actuator Supply Voltage
SHFTLCK_ALLWTransmission Range Shift Lock Output Allow
SHFTLCK_ALLW_FTransmission Range Shift Lock Output Allow Status
SHIFT_AShifting In Progress on Shift Fork A
SHIFT_BShifting In Progress on Shift Fork B
TCILTransmission Control Indicator Light
TCS_DEPRESTransmission Control Switch Pressed
TCS_STATETransmission Control Switch Requested State
TR_A_DCTransmission Range Sensor Input A Duty Cycle
TR_A_POS_MEASTransmission Range Sensor A Position - Measured
TR_A_URTransmission Range Sensor Input A Unreliable
TR_B_DCTransmission Range Sensor Input B Duty Cycle
TR_B_POS_MEASTransmission Range Sensor B Position - Measured
TR_B_URTransmission Range Sensor Input B Unreliable
TR_CORRECTEDTransmission Range Sensor Position - Corrected
TR_CRANKTransmission Range Input Allowing Engine Start
TR_CRANK_FPark Neutral Starter Enable Output Fault Detected
TR_SUPPLY_FTransmission Range Supply Voltage Output Fault
TRAN_RATTransmission Gear Ratio
(1) Clutch A = Clutch 1 (2) Clutch B = Clutch 2
(1)Clutch A = Clutch 1
(2)Clutch B = Clutch 2

ACCESSING PIDS

Clutch - 1

  1. Using the scan tool, navigate to the TCM Adaptive Learning sub menu.
  2. Select PCM.
  3. Select transmission.
  4. Select clutch system test.
  5. Follow the instructions displayed on the scan tool.

Clutch - 2

  1. Using the scan tool, navigate to the TCM Adaptive Learning sub menu.
  2. Select PCM.
  3. Select transmission.
  4. Select clutch system test.
  5. Follow the instructions displayed on the scan tool.