Ford DPS6 Dual Clutch Reset and Reinstall Tool Set

This is the DPTOOL D546 reset set for the Ford DPS6 PowerShift dry dual clutch, the pack Ford sells as F1FZ-7B546-B and later supersessions. It is for anyone who has the clutch out of a Focus or Fiesta and needs it to go back on the input shafts at the correct height, whether the transmission came out for input seal leaks, a clutch fork, a TCM housing job or engine work behind it.

K1, K2 and the wear adjusters

Each of the two clutches in a DPS6 pack, usually called K1 and K2, has a built-in wear adjuster that takes up slack as the linings wear. While the pack is installed, those adjusters are held. Once it comes off the shafts, the K1 and K2 adjuster springs trip and the assembly springs out to whatever position it had worn itself into. A pack in that state will not seat on the shafts, and forcing it leaves clutch clearance wrong. Ford resets the pack with its own tool, 307-676. The D546 does the same job with a press plate, spacers and lock blocks that reach both adjusters.

Signs the reset was missed or is needed

• A used pack that will not slide fully onto the input shafts
• Shudder, slip or flare right after a seal or fork job where the clutch was reused
• Clutch adapts that will not complete after reassembly
• Bent cover tabs from trying to press the pack home without a fixture

Check the cause first

Shudder on a PowerShift is often oil on the dry linings from leaking input shaft seals, the condition behind Ford TSB 16-0109, but actuator motors and the TCM produce similar complaints. Our DPS6 diagnostic guide covers the actuator swap test and the TCM codes, and an actuator set fixes the outside-the-case faults without touching the clutch. If the clutch itself is contaminated, replace it rather than resetting it.

Fitment

The listing applies the D546 to the Ford DPS6 dry dual clutch in the 2011-2018 Focus and 2011-2019 Fiesta, built around clutch assembly F1FZ-7B546-B and its supersessions. North American Focus models with the DPS6 started in 2012, so a 2011 Focus here is a carryover from the listing. Match the clutch part number on your pack, or send the year and VIN. The case measures about 18 x 15 x 4 in and the kit weighs about 13.9 lb. See the rest of our transmission tools for pullers and seal installers.

Reset sequence and install notes

• Pull the pack with a three-jaw puller that bears on the input shaft, such as the DPS6 dual clutch remover and installer kit.
• Seat the pack in the press plate. Press K2 first until its lock buckle catches, then press K1 until it latches. Doing them in that order is what the listing calls for; stop as soon as each one locks.
• With both adjusters reset the pack is back at install height. Replace the input shaft seals, reset the actuators, and install the pack as you would a new one.
• Refill the gearbox with Motorcraft XT-11-QDC. Then run the shift drum, range sensor and clutch adaptive relearns with a scan tool.

In what order do I reset K1 and K2?

Press K2 first until its lock buckle catches, then press K1 until it latches. Stop as each one locks; there is no benefit to pressing further.

Which clutch assembly is this reset set made for?

The listing is built around Ford DPS6 clutch assembly F1FZ-7B546-B and its supersessions, used in the Focus and Fiesta.

Why will my used DPS6 clutch not go back on the shafts?

Removing the pack trips the K1 and K2 adjuster springs and the assembly expands to its worn position. It has to be reset to install height before it will seat.

Is a relearn needed after reinstalling a reset clutch?

Yes. Treat it like a new clutch: run the shift drum, transmission range and clutch adaptive relearns with a capable scan tool before road testing.

Does this kit remove the clutch?

No. It resets the pack once it is off. You need a separate remover and installer kit to pull the pack from the input shafts.

• Ford PowerShift DPS6: Diagnosing Dry-Clutch Shudder, Seal Leaks, and TCM Failures