10 Fusion-Hybrid

Many thanks to all those who posted on this issue and to the Ford dealer in Canada who discovered the fix. I got my 2010 FFH BECM and PCM software updated yesterday and the EV mode problem is totally fixed. I'm really happy! Like others, my early 2010 FFH started having the problem in the fall of '19 (at 82k miles). I took it to a Ford dealer who had their hybrid expert look at it for 5 days and pronounced it needed a new HVB - for $8k plus labor. That was before the TSB came out. To their credit, they recommended not getting a new HVB. The fordfusionhybrid forums pointed me in the right direction. I tried the Forscan program and bbfly OBDII setup but it was more complicated than I was up for so I paid to get the work done. Ford has incorporated the changes into software package updates that a local shop was able to install using their Ford IDS tool and the TSB number. It cost more than the dealer quoted because they had to pay Ford to get the updates but I chose this shop anyway.

Keeping the oil level a bit low is the answer. Yes, I'm 4 years later than you guys dealing with this problem but after 3.5 years of excellent fuel economy and performance with our 2010 Fusion Hybrid I had my first experience with the oil smoke a few months ago when needing to accelerate hard on a freeway entry ramp. Couldn't believe it came from my car at first but then it happened again a month later. A big blast of grey smoke left behind. It's definitely oil and had me concerned the engine was losing it's piston ring sealing after only 36,000 miles. After reading this blog I changed the oil and filter and only put in 4.5 qts. with the dip stick reading half way up the OK range. A couple of full throttle trials and no smoke. Thank you much, Noel, for providing this answer. It alleviated my concerns and avoided taking the car in to the dealer for a cylinder leak-down test.