2010 - 2012 Fusion Hybrid High Voltage Battery TSB at 10 Years of Age

[billford]

Ford released an official TSB about reprogramming the PCM and Battery modules for the concern of lack of electric vehicle operation at aprox. 10 years of age. 

Print out the TSB and show your dealer for reprogramming. Looks like it may be covered under extended emissions warranty??

 

For the people who used Forscan as a work around, this TSB may or may not work as PCM data has been altered and a mismatch results between the PCM and Battery module. If you get the official Ford fix on the Forscan altered vehicle, report back to see if the programming worked. 

 

But if your car is untouched, this TSB should work with no issues. 

2010 to 2012 Fusion Hybrid.pdf

Edited April 28, 2020 by billford

[PaulGo]

Thanks for the update.  I will wait to get feedback to see how it works.  I would assume when they reprogram the modules the new program would completely overwrite the old program and it would assume the car is 10 years.   Hopefully this reprogram will take in all the factors needed to make an effective fix.  I would think it should consider not only the battery age but the miles driven and  the actual condition of the HV battery.  

Edited April 29, 2020 by PaulGo

[PaulGo]

I also think Ford should compensate the owners for all the money they spent trying to fix a problem created by Ford's faulty programming.

[Ffh1]

Thanks billford !

Edited April 29, 2020 by Ffh1

[SunnyB]

Thanks much!  I've actually had the symptoms for a few months.  My average mpg dropped from 40 to about 30.  I was waiting for Spring to make sure the cold weather wasn't causing it. I've had my car for 8 yrs/81K miles.    

 

So is this merely a recognition that the batteries become weaker with age?

 

Does the new software "correct" the reduced electric operation or compensate for it?  If the latter, that seems to imply I'm never going to get 40 mpg again.

[lolder]

8 hours ago, SunnyB said:

Thanks much!  I've actually had the symptoms for a few months.  My average mpg dropped from 40 to about 30.  I was waiting for Spring to make sure the cold weather wasn't causing it. I've had my car for 8 yrs/81K miles.    

 

So is this merely a recognition that the batteries become weaker with age?

 

Does the new software "correct" the reduced electric operation or compensate for it?  If the latter, that seems to imply I'm never going to get 40 mpg again.

The reduction in EV operation is due to OEM software that reduces the HVB output as a function solely of chronological age. Tests by the US government and anecdotal reports show that the HVBs have suffered very little degradation. The repair should restore close to normal operation.

[SunnyB]

On 5/1/2020 at 11:57 PM, lolder said:

The reduction in EV operation is due to OEM software that reduces the HVB output as a function solely of chronological age. Tests by the US government and anecdotal reports show that the HVBs have suffered very little degradation. The repair should restore close to normal operation.

With the reprogramming, will it consider the battery age, miles and battery condition?  There may be little degradation now, but will there be a problem when there is degradation at some point in the future? 

Edited May 5, 2020 by SunnyB

[lolder]

The D.O.E. testing showed 8% capacity reduction at 160k miles. Prii have functioned normally with 60% reduction. The car will operate so long as the HVB doesn't fail open circuit. There have been no reports of this anywhere on forums. The OEM software also stopped re-conditioning events which have been restored by the fix. Much better for the HVB. 

[fun4u]

I fought with Ford and my dealer for more than a year until someone on this forum directed me to a Canadian dealer who knew the fix.  That was in late 2018. My six months of appeals to Ford Motor went to several layers of management, and I finally got results when I wrote to the Chairman's Office!  Ford eventually reimbursed me for over $500 in repairs, but refused, of course, to admit any responsibility. I'm glad to see that Ford has FINALLY issued a tech bulletin so others can get the fix with much less trouble than I experienced.

[mmtphoto]

On 4/28/2020 at 10:10 PM, PaulGo said:

I also think Ford should compensate the owners for all the money they spent trying to fix a problem created by Ford's faulty programming.

 

 

amen-I'll add I've done this for others I know who have 2010-12 ford Hybrids (MKZ's, Fusions) and every person was very annoyed that this was 'baked in' to the software.  I know of people who basically dumped their cars because they feared the HVB was nearing the end of life, and some bought their cars at very low prices and they suspect the seller was paranoid about this issue.  Just a dumb idea, another compliment to Allen and others on here who made this fix public, our Fusion is like new at 110,000 miles.

Edited May 7, 2020 by mmtphoto

[Matt]

Hi, do you still have a copy of the TSB document? It is not currently available on the original post. Thanks!

 

EDIT: I found it at https://static.nhtsa.gov/odi/tsbs/2020/MC-10174404-0001.pdf .

Edited May 18, 2020 by Matt

[SunnyB]

On 5/7/2020 at 5:58 PM, mmtphoto said:

 

 

amen-I'll add I've done this for others I know who have 2010-12 ford Hybrids (MKZ's, Fusions) and every person was very annoyed that this was 'baked in' to the software.  I know of people who basically dumped their cars because they feared the HVB was nearing the end of life, and some bought their cars at very low prices and they suspect the seller was paranoid about this issue.  Just a dumb idea, another compliment to Allen and others on here who made this fix public, our Fusion is like new at 110,000 miles.

Much appreciation to those who documented this online.  It has to be noted how long it took for the TSB to be issued.  It is after the 8 year warranty for mine (and most 2010-12 models).  Charged me $236 even though the TSB seems to indicate only .5 hours labor.

 

I like the car, especially the 700 mi cruising range, but now having researched and learned about the HVB replacement cost, don't know how long I'll hang onto to it.  I called around town to see who could diagnose the HVB and even the Ford dealer said they didn't have the equipment to do it.

[lolder]

Don't worry about the HVB replacement. It'll probably be fine for many years.

[SunnyB]

The mpg seems negligibly better since the update, although I haven't driven the car much.  Hard to say because where I live now is so hilly.

 

 

Edited June 8, 2020 by SunnyB

[Edward]

Had the Tech Service update on Friday, took it out for a 127 mile Sunday ride along the Delaware River above New Hope to Easton, level to slightly rolling terrain, 30-45 mph, averaged 55 mpg, like when new.  Before the update had been averaging ~ 31 mpg.  The service rep said that he also updated other modules at the same time.  Total cost $130.00.

[SunnyB]

On 6/15/2020 at 9:36 AM, Edward said:

Had the Tech Service update on Friday, took it out for a 127 mile Sunday ride along the Delaware River above New Hope to Easton, level to slightly rolling terrain, 30-45 mph, averaged 55 mpg, like when new.  Before the update had been averaging ~ 31 mpg.  The service rep said that he also updated other modules at the same time.  Total cost $130.00.

I've finally been able to drive on fairly flat roads and I'm not getting the same results.  Negligible increase to 34 mpg.  Original bill from the dealer was $254.

 

Also strange, fillups are only about 15.5 - 16.0 gallons even though the tank has a capacity of 17.5 gallons.  I take it down to about 10 miles until empty according to the dashboard, and it's still only 15.5 gallons.

[lolder]

There's another 1.5 gal after empty. Don't test this. Let the pump auto shut-off and don't put anymore in. You can damage the emissions system.

[SunnyB]

3 hours ago, lolder said:

There's another 1.5 gal after empty. Don't test this. Let the pump auto shut-off and don't put anymore in. You can damage the emissions system.

No, I never over fill the gas tank.  But it's good to know that when the dashboard says its 10 miles to empty, I actually have another 1.5 x 34 miles = 51 miles to go if needed.

[lolder]

In today's uncertain times I would never go below 1/3 tank.

[Waldo]

On 7/1/2020 at 9:36 PM, lolder said:

There's another 1.5 gal after empty. Don't test this. Let the pump auto shut-off and don't put anymore in. You can damage the emissions system.

 

I've heard a lot of reasons to not run your car to empty, but damaging emissions is a new one.  What specifically could be damaged?

[SunnyB]

On 7/7/2020 at 9:31 PM, lolder said:

In today's uncertain times I would never go below 1/3 tank.

Don't know what that's about.  Gas stations are still open as usual where I live.  No problem.  I'd take it down to the last 10 miles if I knew where that was. 

Edited July 13, 2020 by SunnyB

[lolder]

On 7/8/2020 at 8:02 AM, Waldo said:

 

I've heard a lot of reasons to not run your car to empty, but damaging emissions is a new one.  What specifically could be damaged?

I think you can get gas in the charcoal canister.

[mwr]

1 hour ago, lolder said:

I think you can get gas in the charcoal canister.

I think you two are talking about different things. Waldo about reasons to not run your car to empty, you (lolder) about not over-filling the gas tank.

[Waldo]

Exactly, you get gas in the charcoal canister when you overfill.

[mwr]

2 hours ago, Waldo said:

Exactly, you get gas in the charcoal canister when you overfill.

I will say that once I overfilled to the max (and got 700 miles from the tank) with no adverse effects that I know of. But I won't do it again.