Mondeo Mk4 Ecoboost: the Powershift problem and the manual solution

20 December 2023 - Reading time: 2 minutes

The first-generation Powershift gearbox on the Mondeo Mk4 has a notorious reputation. I hoped it wouldn’t be that bad — at least on the EcoBoost — but it was.

Despite regular maintenance — clutch replacements, seals, fluid changes — the gearbox finally gave up. One November evening, it started skipping the even gears. This points to a failing valve body, meaning a full teardown, inspection, and repair — expensive and inconvenient.

So, I went with plan B: convert to a manual gearbox, which proved surprisingly complicated on the EcoBoost.

Manual Mondeos with the 2.0 EcoBoost engine are extremely rare, and I couldn’t find parts at breakers. Some

nnew parts aren’t offered either, so I improvised after extensive research:

• Manual gearbox from a facelifted Focus Mk3 ST
• New original shift cables
• New original clutch pedal
• Brake pedal from a Mk4 diesel
• LUK clutch and flywheel kit
• Clutch hydraulic lines from Mk4 diesel
• Aftermarket driveshafts
• New gearshift selector housing with a refurbished gaiter from a diesel donor

The electrical side required adding three wires: reversing switch and a clutch pedal position switch for the 75% clutch travel cut-off (BOT).

A bit of programming later, and the car drives perfectly. Honestly, I almost regret not converting it sooner — could’ve saved some money and headaches.