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Discussion Starter #1
I started a similar thread in another part of the forum but I wanted to put one here where I thought it was appropriate.

My Fiesta, with the dual-clutch automatic transmission has had a bearing or gear noise when in reverse from Day 1 (it can sound pretty sloppy at slow speed as if something was rolling around in the transfer case). I've also noticed some 'slapping' of downshifts when coming to a stop. I took it to my Ford Dealer last week. They immediately confirmed the noise and said they would get back to me after conferring with Ford. This morning, I received a call from the service manager who said they wanted me to come in so they could run a test (that would take about an hour). The SM commented that it is quite possible that the transmission may have to be replaced :)eek:); so, I'm taking it in tomorrow morning and wondering what the outcome will be.

I'm throwing this out there in case anyone else might be experiencing the same thing; hopefully, I'm the only one and that I'm dealing with something that is easily corrected.

Does anyone know if the european Fiesta has had the DCT? If it has the DCT, how has the reliability been? I know these DCT's are not that new and I'm hoping that Ford did their homework in bringing a well-tested product to the US.

Thoughts?
 

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That's too bad - I hope they fix it up quick for you.

One thing I noticed while listening to the annoying 'unwrap' mp3s was that the DCT is designed to last 150k mi. I know nothing about trannies, is that a long or short time? It struck me as rather short (I plan on putting at least twice that on the fiesta)... then again, maybe it's totally acceptable and I should start saving for a new transmission once I pay the car off (although I'm pretty sure i'll hit 150k before then - i'll be averaging around 40k a year for the first four years)
 

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Discussion Starter #3
Same car!

You (anverc) and I appear to have the same exact car (I have a SES Hatch Candy Apple Red will all factory options)? 40K annual miles is some serious stuff; how many miles are you driving daily? Any transmission in any car would be questionable after 150K miles unless it's a HD truck transmission.

I'm a little annoyed that I'm dealing with this problem; especially right from the start. I traded a 2005 Mustang GT in for this car (mostly out of neccessity because of my daily commute which is 80 miles round trip) and I don't need these kind of problems. Here's my list so far:

1. DCT bearing or gear noise (possible replacement in the works?)
2. Inaccurate gas gauge (possible re-calibration or replacement?)
3. Loose windshield molding

Lastly, I drive totally civil so I can maximize my gas mileage (hence the reason why I got rid of my Mustang for a fuel-efficient car) and I'm barely averaging 34 MPG. with almost 1200 miles on the odometer, I expected to be closer to 40 MPG (as advertised!). I don't know what the expected break-in period is for the motor so I'll give it a little more time before I start inquiring with my dealer.
 

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The PowerShift Dual Stage Clutch gearbox is exclusive to the US market Fiesta's.
 

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You (anverc) and I appear to have the same exact car (I have a SES Hatch Candy Apple Red will all factory options)? 40K annual miles is some serious stuff; how many miles are you driving daily? Any transmission in any car would be questionable after 150K miles unless it's a HD truck transmission.

I'm a little annoyed that I'm dealing with this problem; especially right from the start. I traded a 2005 Mustang GT in for this car (mostly out of neccessity because of my daily commute which is 80 miles round trip) and I don't need these kind of problems. Here's my list so far:

1. DCT bearing or gear noise (possible replacement in the works?)
2. Inaccurate gas gauge (possible re-calibration or replacement?)
3. Loose windshield molding

Lastly, I drive totally civil so I can maximize my gas mileage (hence the reason why I got rid of my Mustang for a fuel-efficient car) and I'm barely averaging 34 MPG. with almost 1200 miles on the odometer, I expected to be closer to 40 MPG (as advertised!). I don't know what the expected break-in period is for the motor so I'll give it a little more time before I start inquiring with my dealer.

I didn't get leather (vegan), only options I got were 301A and Moonroof. I plan on adding the euro spoiler shortly after the car arrives.

I actually only drive 12 or so miles a day. However at the end of August my wife is going to be moving 180 miles away to start her doctorate at URI and I plan on going out there every weekend while she's in school. I suppose this is only really an additional 12-13k miles a year. I also managed to put 14k on my Escape in the last year (trips to visit family, see shows, etc...). So perhaps 40k is extreme and I'm only going to barely hit 30k. Now that you've forced me to do the math I feel slightly better ;)

I think you're going to have to find the sweet spot for the way you drive with the fiesta. The automatic transmission is quite a bit different than other cars so hypermiling in a fiesta is probably a lot different than doing so in, say, a sentra. My wife is only averaging 28mpg right now... but she guns it out of stops and doesn't like to use cruise control. I'd suggest hitting reset on MPG gauge while you drive, or spend 150 on a monitoring tool so you can see when the MPG suffers and when it's at its best. Knowing these variables will help you greatly in learning how to maximize your MPG.
 

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Chances are that Ford wants that transmission back for analysis, and they don't want to risk the perception of a poorly made part (given how important the Fiesta is). I've heard of similar things in other vehicles that have been given high prominence from a lot of other manufacturers.

Although dealer trips can be frustrating, it's probably in the best interest of owners and potential owners to have it looked at to make sure there are no problems down the road.
 

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MGREEN how far and how fast in reverse do you have to go ? I have the DCT also and I haven't noticed any noise but I really haven't been in reverse but maybe 3 times in 5 days and then I probably only had to back up the length of the car.
 

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Let the car sit for a second before shifting in reverse. Also reset your trip computer to calculate the MPG accurately.
 

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Discussion Starter #10
At the dealer this morning for the DCT issue

So I went into the dealer this morning and they can ran a test on the transmission per Ford's direction. In drive, the DCT runs fine with no issues. They ended up loading an updated software patch (noting that the computer adapts to my driving habits). My concern addresses a fairly loose sounding bearing/gear noise that I hear when rolling 'slowly' in reverse (like pulling out of my driveway or a parking spot); almost like something is flopping around in the transfer case. The mechanic heard the noise and he and I both agreed that the patch Ford recommended most likely will not eliminate this noise. After about 150 to 200 miles, if the sound is still there, Ford is going to replace the transmission.

One bright spot, after the patch was downloaded, my MPGs have appreciably increased. On the way to my office, my MPG went from an average of about 34 to 39; and, if I had stayed on the highway a little longer before I had to exit, I'm confident I could have gotten the MPG easily over 40.
 

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They ended up loading an updated software patch ... my MPGs have appreciably increased ... from an average of about 34 to 39.
interesting... i wonder if the forums members who are having a hard time getting their MPG up just need to get this patch applied.
 

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As understand it, the DCT is a self-shifting MANUAL transmission, hence the name DUAL CLUTCH. It is unlike a traditional automatic that uses hydraulics and fluids to change gears. Instead, the clutches alternate the shifting as you accelerate or decelerate. Therefore, I would assume the 150k mile replacement would be the CLUTCHES, not the entire transmission. Sounds a whole lot cheaper. I am no expert on this, but that is how the dealer explained it to me.
 

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interesting... i wonder if the forums members who are having a hard time getting their MPG up just need to get this patch applied.
I'm sure his fuel mileage did not improve, it's just that it would have been zeroed out with the new downloaded patch to his computer (that's why Marc recommended to him to reset the trip computer). MGREEN11 then went directly on the highway after the reset where he would have expected the better fuel mileage.
 

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Discussion Starter #14
Bearing noise still there

(iamz) I'm sure his fuel mileage did not improve, it's just that it would have been zeroed out with the new downloaded patch to his computer (that's why Marc recommended to him to reset the trip computer). MGREEN11 then went directly on the highway after the reset where he would have expected the better fuel mileage.

I think you're right; however, the dealer never reset the MPG monitor. I know if you reset it and then immediately jump on the highway, heck, you could probably get 45+ MPG because all its doing is averaging highway miles.

I know my reverse noise in the tranny is still very much there so it looks like I'll be getting a new one.
 

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Awesome increase~

Congrats on the increase in MPG's hope the tranny swap doesn't keep you down long...
 

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Discussion Starter #16
Noise is gone??

Ok,so I've driven the car another 200 miles since the dealer loaded the patch; interestingly, the noise has recently disappeared. The last time I spoke to my dealer (mid last week), the noise was still there and we were still pondering a transmission replacement. At this point, it doesn't look like a new tranny is necessary. My mileage has been up and the car is running great.
 

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Ok,so I've driven the car another 200 miles since the dealer loaded the patch; interestingly, the noise has recently disappeared. The last time I spoke to my dealer (mid last week), the noise was still there and we were still pondering a transmission replacement. At this point, it doesn't look like a new tranny is necessary. My mileage has been up and the car is running great.
Excellent news! Hopefully the noise will never return. But I still wonder what could have caused the noise in the first place?
 

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Discussion Starter #18
(Paradocks) "But I still wonder what could have caused the noise in the first place?"

Good question. No sooner did I post my earler reply on this did I get a call from the dealer. He mentioned that Ford wants the shop to pull the wheel hub from the front left side (where mechanic and I have heard the noise) and investigate what they find. I told him that I think the noise is gone and would get back to him in a day or so so I can confirm before they get crazy taking stuff apart. I'll see what I have in a day or so.
 

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I was doing a search somewhere online when I first got my car and found an article talking about the 150k life. They said it is a sealed transmission. Just drive it till 150k or so. Not made to be serviced. Then buy a new one. I am not sure where I found it but I figured I would share.
 

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I was doing a search somewhere online when I first got my car and found an article talking about the 150k life. They said it is a sealed transmission. Just drive it till 150k or so. Not made to be serviced. Then buy a new one. I am not sure where I found it but I figured I would share.
As someone else mentioned, change the tranny fluid and replace the dry clutches and go another 150k. Probably not too expensive.
 
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