Ford’s PowerShift (DPS6) transmission, used in the 2012–2016 Ford Focus and 2011–2016 Ford Fiesta, is one of the most widely documented transmission failures in recent automotive history. The dual-clutch unit became notorious for premature clutch wear, low-speed shuddering, erratic shifting, and control module failures, problems that affected hundreds of thousands of vehicles and ultimately led to a $77 million class action settlement.

Factory warranty coverage has long since expired for most of these models, leaving owners responsible for repairs that can run $1,000 to $2,000 or more. Here’s what to know about the most common transmission failure points, repair costs, and how to protect yourself if you own or are considering one of these vehicles.

What Made the PowerShift Different and Why It Failed

Ford has an extensive history of selling small cars in Europe, so it made sense to turn to German transmission manufacturer Getrag to help develop the PowerShift unit. Dual-clutch transmissions aren’t unique to Ford; you’ll find them in brands like Audi, BMW, and Porsche. Instead of using a torque converter, they rely on two clutches: one for odd gears, the other for even. That setup lets the next gear be ready ahead of time, so shifts happen quicker and with less interruption.

However, while most dual-clutch transmissions use a wet clutch (oil-cooled) design, the PowerShift unit features a dry architecture, which is cheaper to manufacture. As it turned out, this configuration is vulnerable to premature wear under everyday driving conditions. The dry-clutch design proved more susceptible to wear under stop-and-go driving conditions than many owners expected.

Adding to the troubles is the PowerShift transmission’s control system, which combines electronic controls with electro-hydraulic components to operate the clutches and gear selection. Failures within this system can cause the transmission to hesitate, shift unpredictably, or even feel like it has dropped into neutral while the vehicle is in motion.

Ultimately, the PowerShift transmission couldn’t stand up to the rigors of real-world driving.

Most Common Failure Points and What They Feel Like

PowerShift transmission troubles aren’t limited to a single component or trouble spot. Here’s a broader look at what’s involved.

Clutch Pack Wear and Low-Speed Shudder

One of the first signs of problems with a PowerShift transmission is a low-speed shudder or jerking. This typically occurs between 5 and 15 mph when the transmission repeatedly engages and disengages the dry clutch. The issue shows up most in stop-and-go driving. The clutches are always working, which wears them down faster and can foul the surfaces. Ford issued multiple technical service bulletins (TSBs) in response.

Numerous owner reports on file with the National Highway Traffic Safety Administration (NHTSA) and CarComplaints consistently describe a pattern of jerking, shaking, or bucking during low-speed acceleration. CarComplaints tagged multiple Focus and Fiesta model years with its “Avoid Like The Plague” or “Clunker” labels. Consumer Reports has also flagged the transmission as a major reliability concern for these models.

Mechatronic System and TCM Failures

Owners of the 2012–2016 Ford Focus and 2011–2016 Ford Fiesta should be aware that malfunctions often extend beyond clutch wear into the transmission’s control system. This transmission relies on its control system and internal components staying in sync. When that doesn’t happen, the symptoms don’t take long to appear.

Drivers may notice:

• Hesitation when accelerating after a stop
• Delayed or rough gear engagement
• Sudden loss of power as if the car shifted into neutral
• Unexpected power surge after the transmission re-engages

The PowerShift transmission relies on a transmission control module (TCM) and associated electro-hydraulic control components to operate the clutches and shift gears. Failures within this system were a widespread source of PowerShift transmission problems and can lead to hesitation, rough shifting, delayed engagement, or loss of drive.

When the TCM or related control components fail, the transmission loses its ability to control when and how the clutches engage and gears shift. This can trigger:

• Diagnostic trouble codes (warning lights)
• Vehicle stuck in a single gear
• Loss of forward or reverse movement

Several owners report that TCM failures aren’t isolated events. Complaints compiled by CarComplaints show that symptoms often return even after the module has been replaced, suggesting that faults within the broader control and actuation system can persist beyond a single repair.

Repair Cost Ranges After the Warranty Expires

As part of a customer satisfaction program, Ford extended the factory protection for the PowerShift transmission. Unfortunately, powertrain coverage was only stretched to seven years or 100,000 miles (from five years or 60,000 miles). This extra safeguard expired years ago, so owners are on the hook for any repairs. However, Ford extended warranty coverage for TCM-related repairs to 10 years or 150,000 miles.

Take note that car repairs have gotten more expensive in recent years. According to U.S. Bureau of Labor Statistics data, the cost of motor vehicle maintenance and repair has increased by over 33% since 2021, with particularly sharp increases in 2023.

Consider what fixing a PowerShift transmission without a warranty could cost:

Clutch Replacement

A clutch replacement is a common repair for Fords with a PowerShift unit. RepairPal estimates that Ford Focus owners can expect to pay $1,080 to $1,370 for the work, while costs rise to $1,530 to $1,970 for those with a Ford Fiesta in the driveway. Keep in mind that because clutch wear is an underlying condition with these transmissions, this may not be a one-time repair.

Transmission Control Module Replacement

Ford commonly refers to this portion of the PowerShift control system as the transmission control module (TCM). Because repair terminology can vary, owners may also see references to the transmission’s mechatronic or electro-hydraulic control components when discussing PowerShift repairs. According to repair data cited by UpFix, replacing the TCM costs about $1,200. Because of the extended TCM warranty, owners should verify their eligibility before paying out of pocket.

Ford’s Recall and Settlement History

While the affected Focus and Fiesta models had numerous recalls, there was no Ford transmission recall for the PowerShift units used in these vehicles. The company issued numerous service bulletins and selectively extended the warranty coverage.

Most of the remedies available to owners, such as the extended factory warranties, came from the primary U.S. class action suit, Vargas et al. v. Ford Motor Company. The lawsuit was originally filed in 2012 and covered 2011–2016 Fiesta and 2012–2016 Focus owners. The settlement, which received final court approval in 2020, covered 1.9 million class members and provided eligible class members access to more than $77 million in potential benefits, including cash payments and buyback opportunities, subject to the settlement terms.

Years to Avoid vs. Years to Consider

If what you’ve read hasn’t scared you away from the Focus and Fiesta, and you’re still considering buying one of these Fords, then at least focus on the bad and less-bad model years.

Highest-Risk Years

If there are any PowerShift-equipped Fords to run away from, it’s the 2012–2014 Focus and 2011–2014 Fiesta. The number of owner complaints on file with NHTSA and CarComplaints runs into the triple digits (or higher).

Even if one of these cars has already been corrected for transmission troubles, history shows that these models may require multiple repairs for the same issue. Clutch wear continues, and replacing the transmission control module doesn’t always appear to be a permanent fix.

Improved but Not Problem-Free

A review of owner complaints shows transmission issues have settled down, but haven’t evaporated for the 2015 and 2016 editions of the Focus and Fiesta. Ford introduced software updates and moderately improved hardware to improve reliability.

However, you should still approach these vehicles with caution. CarComplaints still applies the “Clunker” badge to the 2015–2016 Focus. Yet, surprisingly, the 2016 Fiesta actually earned an “Awesome” designation.

What to Look for When Buying a Used Ford Focus or Fiesta

If you’ve decided to pursue a Focus or Fiesta with a PowerShift transmission, hopefully you’ll at least target the 2015 and 2016 model years. From there, do a deep dive into the car’s service history, paying special attention to clutch replacements and transmission control system repairs. Don’t make any assumptions or take a seller’s word without hard evidence. Lastly, have the vehicle inspected by a technician experienced in PowerShift repairs.

How a VSC Covers the Gap for Qualifying Transmission Repairs

Given the age of these troublesome Focus and Fiesta models, the factory warranty has expired (except for some examples eligible for additional TCM coverage). The class action settlement covers anyone who purchased or leased a 2011–2016 Ford Fiesta or 2012–2016 Ford Focus equipped with a PowerShift transmission. The settlement received preliminary court approval on April 25, 2017, and final approval on March 5, 2020. That leaves thousands of owners responsible for repairs, including for expensive PowerShift transmissions.

An extended car warranty (also called a vehicle service contract or auto protection plan) may help reduce the financial impact of mechanical breakdowns after your factory warranty expires. The idea behind an extended warranty is to help make the cost of eligible repairs more predictable through scheduled payments. Plus, depending on the plan, it may also help cover eligible repairs to systems such as the engine, air conditioning, electrical, suspension, steering, and brakes.

Endurance takes a different approach to vehicle service contracts by being a direct claims administrator. Unlike some competitors, Endurance customers don’t have to work with third-party operators; claims are handled in-house. This allows repair facilities to work directly with Endurance throughout the claims process.

Change Gears with Protection from Endurance

If you already own a car with a PowerShift transmission or are considering buying one, think about how an Endurance Warranty plan can help reduce the financial uncertainty associated with unexpected repairs. Endurance offers options that provide essential powertrain protection, and the top-tier Supreme program is Endurance’s broadest exclusionary coverage plan. There are intermediate programs that balance coverage and cost. Endurance also offers options for commercial-use and high-mileage vehicles.

All Endurance plans include 24/7 roadside assistance with towing support, trip interruption protection, rental car reimbursement, and flexible payment plans. We also offer a free year of Endurance Elite Benefits with every new contract, which includes tire coverage, key fob replacement, windshield repair, and more. Customers can choose any licensed facility for covered repairs, including dealership service departments and transmission shops.

Discover how to protect your Ford or other vehicle with an Endurance auto protection plan. Your plan options are available by requesting a FREE quote or by visiting the Endurance online store. Do you have more questions about protecting your car? Call an Endurance plan advisor at (800) 253-8203.

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