Gearbox Tuning Remap Guide: Case Study – Ford Transit Custom Auto Remapped for Work & Towing

Meta Description:
See how we transformed a Ford Transit Custom 2.0 TDCi automatic with ECU + TCU tuning. This case study shows real results for torque, shift behaviour, towing control, and daily drivability.

Primary Keywords:
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Secondary Keywords:
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🔧 Vehicle Overview

Customer: Local tradesman (Burton-on-Trent)
Van: 2019 Ford Transit Custom 2.0 EcoBlue TDCi 130PS
Transmission: 6-speed automatic (conventional auto, not Powershift)
Usage:

  • Daily tool transport (~500 kg payload)

  • Regular towing of a 1.3-tonne trailer

  • Mix of urban, A-road, and motorway driving

❌ Initial Complaints

Before tuning, the customer reported:

  • Poor throttle response when loaded

  • Early upshifting in 2nd–4th gears

  • Frequent gear hunting at ~40–50 mph

  • Weak pulling power with trailer on hills

  • Annoying lag on roundabout exits or overtakes

🎯 Tuning Goals

Priority Description
✅ More torque For load and trailer performance
✅ Better shift behaviour No early changes, smoother control
✅ Kickdown improvement More responsive throttle
✅ Safe EGTs and temps For long trips and towing
✅ Improved fuel efficiency Reduce urban shifting and gear hunting

🔬 Diagnostics & Preparation

  • ✅ No fault codes present

  • ✅ Gearbox temperature and fluid healthy

  • ✅ ECU and TCU read via OBD (Flex tool)

  • ✅ Baseline data logs captured:

    • Boost response

    • Throttle % vs shift RPM

    • Gear changes under load

    • Fuel trims and EGR behaviour

🧠 ECU Tuning – Stage 1

We custom-mapped the ECU for:

  • +35 bhp increase (approx. 130 → 165 bhp)

  • +80 Nm torque increase (360 → ~440 Nm)

  • Smoothed torque curve = no flat spots

  • EGR recalibrated for cleaner response

  • Boost adjusted to support mid-RPM pull

  • Factory safety features retained

✅ Power now available from just 1,400 RPM — ideal for trailer launches and hilly B-roads.

⚙️ TCU (Gearbox) Tuning Strategy

We adjusted:

  • Shift RPM maps in D and S mode

  • Torque limiters (previously capped power in 2nd and 3rd)

  • Kickdown response delay reduced

  • Line pressure raised slightly to improve firmness under load

  • Manual mode shift control refined (less lag)

✅ Gearbox now holds gears better under throttle and avoids awkward early upshifts on light inclines.

📈 Post-Tune Results

Metric Before Tuning After ECU + TCU Tune
Torque (Nm) 360 Nm ~440 Nm
0–30 mph (with trailer) ~5.8 sec ~4.5 sec
30–70 mph kickdown Delayed, gear hunt Smooth downshift, full pull
Urban gear shifting Early + jerky Smoother, holds when needed
Hill climbs (loaded) Frequent kickdown Maintains higher gear longer
Fuel economy (mixed use) 32 mpg 35–36 mpg (post-tune avg)

🎯 Customer Feedback

“It’s exactly what I needed. The van doesn’t feel choked anymore when I’ve got the trailer on. Kickdown is instant now, and it just pulls. And I’m not filling up as often — bonus.”
– Chris, Burton-on-Trent

🧪 Final Checks

✅ Road tested under urban, A-road, and towing conditions
✅ Post-map logs: boost stable, gearbox temp normal
✅ No DTCs, no warning lights
✅ Confirmed gearbox learned new adaptation within 30 miles

📍 Tuning Your Transit or Work Van at Precision Remaps

We offer:
✅ Stage 1 & towing-optimised ECU tunes for Transit 2.0 TDCi
✅ Automatic gearbox (TCU) shift optimisation
✅ DSG and ZF tuning for VW, Mercedes, and Citroën vans
✅ Remapping for long-haul, urban delivery, or towing use
✅ Fleet and fuel-saving maps available

📍 61 Rolleston Road, Burton on Trent
🌐 https://precisionremapsuk.com
📧 car-remapping@outlook.com

✅ Summary: Why Combined ECU + TCU Tuning Works

  • Delivers real performance you can feel

  • Solves gearbox lag, early shifts, and torque limits

  • Great for vans under load or regular towing

  • Safer, smoother, and more fuel-efficient

  • Custom-built to match your exact use case