Case repair PowerShift DCT450 MPS6 (Ford Kuga C-MAX Mondeo / Volvo XC60 XC90 S80) - one hole repair price - 20$

PowerShift DCT450 (MPS6) - is a dual wet clutch robotised transmission, on our market you can mainly find it on Ford Kuga, C-MAX, Mondeo и Volvo XC60, XC90, S80, S40, V60.

It belongs to the class of pre-selective transmissions, it is structurally a mechanical box with two input and two output shafts - one is responsible for even transmissions, the other for odd ones. But at the same time, unlike mechanics, the drum is a complex structure as a clutch - friction discs operating in an oil bath provide the clutch.

We have already told you how Maktrans specialists repair PowerShift boxes, you can read more here::

• Clutch and damper repair PowerShift DCT450 MPS6
• Mechatronics solenoids repair PowerShift DCT450 MPS6
• Mechatronics repair PowerShift DCT450 MPS6

Now  we will consider the repair of the body. As a rule, body repair work is part of the transmission overhaul and is associated with high mileage or improper operation of the automatic transmission. In the DCT450 there are 2 weak points associated with the case:

• bearing of the housing (broken seat)
• the holes in which the gear shafts work — the wearout appears in them and the rod begins to jam, while computer diagnostics can show errors associated with jamming of the forks.

In the photo below - wearout of the hole

The repair consists of drilling a hole on a CNC milling machine and installing a steel sleeve, the internal diameter of which repeats the diameter of the original hole - now we will show how this happens.

Using the guide, we center the lid on the milling and fix

Drilling the hole to the size of the oversized sleeve

The result is the follwing

We measure the inside diameter of the resulting hole with a gauge and make sure that we are "in size"

We drill the remaining holes and we can proceed to the installation of bushings. We also manufacture bushings by ourselves.

We press the sleeve using a special mandrel