DCT Transmissions – Common Problems and Solutions

DCT stands for Dual Clutch Transmission. This is the automatic transmission that combines the classic manual gear set and the mechatronic system that actually shifts the gears. This transmission is very different from a conventional automatic or the CVT type of gearbox.

Anyway, the world has seen a lot of problems with these types of transmissions. First of all, they don't live as long as you may want them to live. Also, they fail to deliver quality and reliability even within their short lifespan.

There are hundreds of well-known common problems with DCT units, and in this article, I want to quickly recap what I've already written in this blog and give you links for further investigation.

Volkswagen Golf DSG transmission

DSG transmissions are well-known for having tons of issues. Especially, the ones with dry clutch. When it comes to early 7DSG units that powered the sixth generation of the Golf, an experienced mechanic may get a light heart attack or something.

The 7-speed DSG can also be different. A lot of modern types of DSG transmissions come with wet clutch and can live quite long without any problems. Also, I personally owned the 6-speed DSG on an old European diesel-powered Passat and it lived more than 250,000 miles (400,000 km) before I sold the car with no problems at all.

But still, you need to be careful with any DSG because it's a dual-clutch transmission with a lot of common issues and very expensive repairs.

7-speed DSG transmissions highlights:

• Average lifespan:110,000-130,000 miles
• Reliability Score:Low
• Prone to minor issues:Yes
• Price for repair after failure:$1,500-$3,000
• Price for replacement:$5,000-$6,000
• Availability of parts:Good
• Common problems:clutch kit failure, control module problems, mechatronic issues.

Kia DCT transmissions

Again, when it comes to DCT transmissions in Kia and Hyundai cars, you should check whether the gearbox has a wet or dry clutch. The models with the dry clutch system are known to be very faulty and they don't live long. Also, they require expensive repairs because the clutch costs a fortune.

One good news is that such transmissions actually can be repaired, not like CVT units. But you will need to spend a lot of money on repair due to parts cost and also the long labor needed to take the transmission off the car and basically take it apart.

The worst part is the clutch. If it fails, you can barely drive and the repair is super expensive. Other than that, Kia DCTs are very good to drive - they offer wonderful dynamics and great fuel consumption.

Kia DCT transmissions highlights:

• Average lifespan:100,000-120,000 miles
• Reliability Score:Low
• Prone to minor issues:Yes
• Price for repair after failure:$1,300-$2,500
• Price for replacement:$3,500-$5,000
• Availability of parts:Good
• Common problems:clutch kit failure, electronic glitches, control module problems, fatal failure.

Ford DCT transmissions

Ford has a dedicated name for its DCT transmission - PowerShift. The US knows only one version of this gearbox - 6-speed PowerShift. In Europe, you can buy the 7-speed PowerShift still in some vehicles.

This is arguably the worst automatic transmission ever made due to fata failures with clutch and electronic control module that are super hard and expensive to repair. There are no options for buying aftermarket parts and used ones will not last long. So, get ready to spend some money.

There is no need to replace the transmission if it fails. Clutch and TCU replacement will help you solve the problems. But still, there is a very high chance that you will spend over $3,000 to bring this transmission back to life.

The 6-speed PowerShift was mainly used in the Focus and Fiesta and people can't stop hating it in all possible forums.

Ford PowerShift transmission highlights:

• Average lifespan:90,000-110,000 miles
• Reliability Score:Low
• Prone to minor issues:Yes
• Price for repair after failure:$1,500-$3,000
• Price for replacement:$3,500-$5,000
• Availability of parts:Poor
• Common problems:clutch kit failure, electronic glitches, control module problems, super expensive repair.

Clutch wear in DCT transmissions

Why does the clutch wear so fast in almost all modern DCT transmissions? Well, you need to know that the clutch wears heavily only in the gearboxes with a dry clutch. Also, in manual transmissions, the clutch pack will wear at 100-150 thousand miles or even sooner, depending on the driving conditions.

The DCT is basically the manual transmission with automated shifting, so there is no way the clutch will remain intact for a lot of miles.

I've written the article about DSG clutch wear - you can check it and find more information about this problem.

Fortunately, you can deal with the clutch wear problem by replacing the clutch in your DCT unit. But the bad news is that the clutch kit is going to cost you a lot of money - about $1,000 for the kit, on average, plus labor.

Clutch wear in DCTs highlights:

• Average mileage:90,000-110,000 miles
• How serious it is:Urgent problem
• Possibility of repairs:Possible
• Price for repair:$1,500-$2,500
• Labor time:10-12 hours
• Can you drive?Usually no
• Common reasons:aggressive driving, natural wear and tear, a lot of city driving with creeping mode.