Pinpoint Tests A: DPS6 Clutch Concern Pinpoint Test

NOTE: Within this test you may notice that certain test steps or actions may have been done previously in a Service Information Pinpoint Test (PPT). Please be sure to fully complete each test step presented as they are used collectively to determine the final repair recommendation. In addition, these test steps and results are recorded to assist Ford engineering teams in the analysis of DPS6 clutch concerns.
This test should only be conducted after completing basic diagnostics, applicable Service Information Pinpoint Tests (PPTs) and then only if directed by the Service Information.
The tools required to complete this test are:

Rotunda Integrated Diagnostic Software (IDS).
Vehicle communication Module (VCM) or (VCM II).

A1: INPUT REQUIRED INFORMATION
- Input the required information in the provided fields below.
  * - Indicates Mandatory Field
  
  Repair Order (RO) Date*
  
  Repair Order (RO) Number*
  
  Repair Order (RO) Line Number*
  
  Dealership's P & A Code*
  
  Go to A2.

A2: READ VEHICLE INFORMATION AND RETRIEVE CONTINUOUS MEMORY DTCS

Ignition ON, engine OFF.
Carry out the TCM self-test.

Have all the DTCs been diagnosed following the directions in the Service Information?

Yes	No
Go to A3.	REFER to the Service Information and DIAGNOSE the DTCs present.

A3: CHECK FOR APPLICABLE FORD SERVICE PUBLICATIONS, FSAS, TSBS AND SSMS

Have the applicable Ford Service Publications, Field Service Actions (FSAs), TSBs and Special Service Messages (SSMs) that apply to the reported customer concern been carried out?

Yes	No
Go to A4.	CARRY OUT the instructions as listed in the applicable TSB, FSA, or SSMs.

A4: CARRY OUT THE TCM ADAPTIVE LEARNING PROCEDURES

NOTE: This vehicle is equipped with an adaptive transmission shift strategy which allows the vehicle's computer to learn the transmission's unique parameters and improve shift quality. After certain service procedures, the re-learn process may require several days before the shift quality is optimized.

Add oil dye to the engine. REFER to Engine System - General Information and any applicable General Service Bulletins (GSB).
Carry out the clutch adaptive learning. Refer to the TCM Adaptive Learning procedure in Transmission Control Module (TCM) Adaptive Learning .
Test drive the vehicle and check for transmission shifting concerns

Does the clutch continue to shudder?

Yes	No
Go to A5.	Go to A8.

A5: RECORD THE TRANSMISSION DATA CLUTCH PID INFORMATION

Using a scan tool, under the Datalogger Powertrain selection for vehicles with the DPS6 transmission, select 'DPS6 Shudder Concern'. This selection provides a pre-selected pick of the PIDs commonly used to diagnose the DPS6 shudder concern. This is available with the IDS R91.01 release or later. The scan tool Datalogger function monitors the following PIDs; ISS_A_RAW, RPM TCM, CLUTCH_A_OPEN, CLUTCH_B_OPEN, GEAR_CMD, APP1
Gently accelerate the vehicle away from a stop while monitoring APP1. With APP1 at 18-30%, record the shudder event.
NOTE: In rare instances the IDS may display a square wave or stair step pattern. This is a result of a software error. The data is not usable for interpretation. Make a new recording using a different IDS.

Using the Playback feature slide, place it over the area of the shudder event.

Courtesy of FORD MOTOR CO.

Slide the line position bar over the high point of the greatest rpm fluctuation (record rpm). Slide the line position bar back to the next closest low point. Verify the low point is identified by scrolling the bar L and R one data point (record rpm).
Subtract the low reading from the high reading. (EXAMPLE-1450-1175= 275.)
* - Indicates Mandatory Field

Enter the difference between the LOW and HIGH readings.*

Is the difference between the LOW and HIGH readings less than 250 rpm?

Yes	No
Go to A8.	Go to A6.

A6: UPLOAD THE VEHICLE SESSION FILE

Hold (saves recordings) the vehicle session on the diagnostic scan tool. Upload the held vehicle session to the Hotline.

Has the held vehicle session file been uploaded to the Hotline?

Yes	No
Go to A7.	UPLOAD the held vehicle session to the Hotline.

A7: CLUTCH REPLACEMENT IS RECOMMENDED
- Test results: The results of the test show that the clutch failed.
- For Ford paid repairs, the DPS6 Clutch Hardware RVC is required when claiming the labor operations published in the TSB or FSA.
  NOTE: New clutch installations may require updated TCM/PCM calibrations. Follow reprogramming instructions indicated in the applicable TSB, FSA, or instruction sheet included with the clutch.
  
  INSTALL a new Clutch Assembly.
  
  INSTALL a new clutch.
  
  Order a replacement clutch and include the validation code on the form.
  
  If this is a Ford paid repair ensure that this clutch test validation code is included on the claim form.
  
  When complete, select the "X" in the top right corner to close this procedure.
  
  New clutch installations may require updated TCM/PCM calibrations. REFER to Clutch And Damper Unit .

A8: DETERMINE IF A FLUID LEAK IS PRESENT

Raise vehicle on hoist.
Remove engine undershield, if equipped.

Visually inspect the clutch housing for evidence of fluid leak.

NOTE: The severity of fluid leak evidence may range from oily residue covering more than 13 square centimeters (2 square inches) of area to a visible drip.

Courtesy of FORD MOTOR CO.

Courtesy of FORD MOTOR CO.

Is evidence of a fluid leak from the clutch housing present?

Yes	No
Go to A9.	The vehicle is operating as designed.

A9: CLUTCH REPLACEMENT IS RECOMMENDED (CONTAMINATION)

Test results: The results of the test show that the clutch is contaminated and should be replaced.
Remove the transmission. Refer to Transmission - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma .
Inspect the crankshaft rear seal for oil leak using the UV (ultraviolet) Leak Detector Kit.
NOTE: New clutch installations may require updated TCM/PCM calibrations. Follow reprogramming instructions indicated in the applicable TSB, FSA, or instruction sheet included with the clutch.

Is the crankshaft rear seal leaking engine oil?

Yes	No
The TSB or FSA does NOT apply. A RVC is NOT required for this repair. REPLACE the clutch due to contamination and repair the leak as required following published Service Information procedures. For Ford paid repairs, use available labor operations per the Warranty and Policy manual.	INSTALL a new Clutch Assembly. REPLACE both inner and outer input shaft seals and the clutch. For Ford paid repairs, the DPS6 Clutch Hardware RVC is required when claiming the labor operations published in the TSB or FSA. When complete, select the "X" in the top right corner to close this procedure.