Description

Ford Fiesta, Focus Service Manual – 6DCT250 Transmission OEM Factory Data

If you’ve ever tried to rebuild a DCT250 with aftermarket specs, you know the drill: stripped bolts, wrong clearances, and a transmission that shifts like a blender full of rocks. This Ford Fiesta, Focus Service Manual kills that guesswork. It’s the exact book Ford dealers used before they went digital – 144 pages of factory-only data for the 6DCT250 dry dual-clutch transmission. I’ve been turning wrenches for 28 years, and I’d rather read a PDF of this than trust any third-party publisher.

144 Pages of Factory Transmission Data

Page 1 kicks off with the specs you actually need: lubricants, fluids, sealers, and adhesives. Ford calls for WSS-M2C200-D2 transmission fluid. Dry fill? 1.8 liters. Service fill? 1.5 liters. That’s not a suggestion – it’s the exact capacity so the clutch doesn’t starve or flood. The manual doesn’t waste ink on theory. It jumps straight to shift fork clearances, synchronizer ring minimums (1.30 mm / 0.051 in), and a full differential shim selection chart from 0.500 mm up to 1.200 mm. Every number is in both mm and inches because some of us still reach for a dial indicator over a digital caliper.

Ford Fiesta, Focus Service Manual – 6DCT250 Coverage

This manual is built for the 6DCT250 transmission only – the one in Fiesta (2011–2019) and Focus (2012–2018) with the dry clutch pack. If you’re pulling a wet clutch DCT, this isn’t your book. But for the dry version, you get the complete gear ratio table: 1st at 3.917, 2nd at 2.429, all the way up to 6th at 0.702 with final drives of 3.89 or 4.35 depending on the gear. Need to match input shaft speeds for a rebuild? The TCM logic and actuator motor specs are right there in the Transmission Description – Overview section. It explains how the two independent clutches engage via actuator motors controlled by the TCM, and how the two input shafts (hollow and solid) work together to preselect gears. That’s the kind of detail that stops a comeback job before it starts.

What Torque Specs Are Included?

Torque values are scattered through the procedures – not listed in a single table on one page because Ford groups them with the step they belong to. You’ll find clutch actuator motor fasteners, shift fork rail bolts, and differential bearing retainer torques embedded in the removal and installation instructions. This is the OEM way: torque here, check clearance there, move on. No generic “tighten to spec” nonsense. If you’re chasing a specific value, flip to the Clutch section – the clutch 1 thickness spec is 26 mm (1.023 in) and clutch 2 is 15 mm (0.59 in). That tells you when the clutch pack is worn past service limit. Pair that with the shift fork clearances (reverse/4th gear fork max 1.85 mm, 1st/5th same max) and you’ve got a complete wear assessment without pulling out a micrometer.

Lubricants and Capacities: Factory Specified Fluids

Ford’s fluid requirements aren’t a suggestion – they’re a reliability requirement. The manual lists WSS-M2C200-D2 as the only approved transmission fluid. Use anything else and the TCM calibration can drift, leading to clutch slip or harsh engagement. The capacities table (page 1) gives dry build fill (1.8 L) and service drain-and-fill (1.5 L). If you’re doing a rebuild after a seal failure, start with dry capacity and adjust after the cooler circuit fills. I’ve seen shops overfill by 0.3 L because they used a generic spec – this manual eliminates that mistake. Ford Fiesta 2002 Wiring Diagram and Ford Fiesta 2002 Workshop Manual – Section: Grupo 5 Carrocería Y Pintura are related resources for older models, but for the DCT250 transmission, this is the only manual you need.

Understand Shift Fork Clearances Before Assembly

Page 2 of the manual gives the clearance numbers for every shift fork and hub sleeve combination. For example, the clearance between 3rd gear shift fork and hub sleeve: maximum 1.725 mm (0.067 in), standard 0.625–1.125 mm (0.024–0.044 in). If you don’t check these with a feeler gauge and replace worn forks, you’ll get gear clash or a fork that jumps out of engagement. The differential shim selection chart takes a measurement from a tool reading (0.500–1.200 mm range) and tells you exactly which shim thickness to install. No guesswork – just measure, read the chart, pick the shim. Ford Fiesta 1.4 TDCI 2004 Technical Manual covers a different engine, but for the transmission side, this is your single source of truth.

When you’re inside a 6DCT250, the TCM holds the key to actuator timing. The manual’s Transmission Description explains how the two clutch actuator motors engage and disengage the dry double clutch unit. One motor controls clutch 1 (odd gears), the other controls clutch 2 (even gears and reverse). Shift drums rotate to select gears via integrated electric motors – the TCM synchronizes everything based on engine load and road speed. If you’re replacing a TCM or reprogramming, the manual includes the actuator home position and calibration steps. This isn’t a wiring diagram; it’s a mechanical and electronic deep-dive. Automotive Industry Overview is a general reference, but Ford’s own document stays specific to the DCT250. Automotive Industry Overview – same external source, different context.

Does this manual cover the clutch actuator motor replacement?

Yes, it includes removal and installation procedures.

What is the difference between dry and wet clutch capacities?

The 6DCT250 uses a dry double clutch. The manual specifies dry fill capacity at 1.8 liters and service fill at 1.5 liters. Wet clutches would require different fluid type and capacity. This manual is specific to the dry clutch DCT250 found in Focus and Fiesta models from 2012–2018 approximately.

Stop chasing aftermarket PDFs that miss the subtle clearances and fluid specs Ford engineered into this transmission. You’ve got the original factory data here – 144 pages of what matters. Access the Factory Manual now and get back to working on the job with real specs.