Transmission diagram PowerShift DCT450 Ford Mondeo
Input block
* Drive shaft
* Driven shaft
* Synchronizers for 1-2 and 3-4 gears
Clutch block
* Double disc wet clutch (one clutch for odd gears, one for even gears)
* Electronically controlled hydraulic system
Gear block
* Gear shafts for odd gears (1-3-5)
* Gear shafts for even gears (2-4-6)
Differential block
* Differential with planetary gear
* Axle shafts
Gear shift mechanism
* Electromechanical actuator
* Shift forks
Hydraulic unit
* Hydraulic module that controls clutches and gear shifting
Electronics
*Transmission Control Module (TCM)
* Sensors and solenoids
Lubrication system
* Oil pump integrated into the gearbox
* Oil filter
Power flow diagram
* 1st gear: The odd clutch is engaged, the 1st gear pinion shaft rotates the 2nd gear gear shaft, which transmits power to the differential.
* 2nd gear: The even clutch is engaged, the 2nd gear shaft rotates the 1st gear shaft, which transmits power to the differential.
* 3rd gear: The odd clutch is engaged, the 3rd gear shaft rotates the 4th gear shaft, which transmits power to the differential.
* 4th gear: The even clutch is engaged, the 4th gear pinion shaft rotates the 3rd gear gear shaft, which transmits power to the differential.
* 5th gear: The odd clutch is engaged, the 5th gear pinion shaft rotates the 6th gear gear shaft, which transmits power to the differential.
* 6th Gear: The even clutch is engaged, the 6th gear pinion shaft rotates the 5th gear pinion shaft, which transmits power to the differential.
Note: Only one gear can be engaged at a time. Shifting between gears occurs by opening one clutch and closing the other. An electronic controller controls the gear shift mechanism to ensure smooth and fast shifting.