Report says Ford aware of issues
Fiesta, Focus sold anyway
Ford allegedly pressed on with the development and manufacture of its six-speed Powershift automatic despite internal complaints and a cavalcade of repair issues, according to a new investigative report from the Detroit Free Press.
The newspaper published a lengthy feature in mid-july on transmission problems experienced by owners of Ford Fiesta and Focus small cars.
According to the report, problems with the transmission — called the DPS6 — arose in testing. The Powershift is a dual-clutch transmission that uses parts that resemble a manual gearbox but is operated by the driver like a traditional automatic. They were intended to reduce weight and provide fuel-economy advantages.
They certainly achieved those goals, but it was apparently at the expense of smooth and reliable operation. Using a dry-clutch system, unlike modern dual-clutch units that use a wet-clutch system that bathes the clutches in oil, the transmission quickly became notable for jerky shifts and the propensity to slip out of gear, even at highway speeds. Internally, this was apparently called an “Unintended Neutral.”
“As years wore on, Ford would make the case in emails, internal documents and an affidavit that if the steering, turn signals and other power worked in the car, then the situation couldn’t be considered dangerous. In theory, people could turn on a blinker and steer to the side of the highway if the car slipped into neutral at 70 m.p.h.,” the Detroit Free Press reported.
As costs and complaints piled up, Ford kept trying to find a fix while creating talking points for those unlucky enough to be in customer-facing positions.
Ford told the Detroit Free Press in a statement that conversations during development about “challenges common to innovative new technology” were “normal exchanges.”
“After the new transmission was on the road, other problems developed. We acted quickly and determinedly to investigate the problems,” the statement said. “While we eventually resolved the quality issues, the solutions were more complex and took longer than we expected. We regret the inconvenience and frustration that caused some consumers.”
Here’s the kicker: apparently, none of this was a total surprise to those on the development teams. Six months before the 2012 Focus began shipping to dealers, a product development engineer wrote in an email to colleagues: “We also cannot achieve a driveable calibration that will get us to production,” and “the clutch torque delivery MUST BE IMPROVED.”
Yet the company pressed on, producing cars equipped with a transmission that has been the catalyst for class-action lawsuits and countless hours of repair work. For many owners, there is still no resolution.