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

[lolder]

On 12/29/2020 at 9:41 PM, SunnyB said:

 

My car supposedly got the update at the dealer, but is still running at 29 mpg.   Interestingly, the problem arose after I got the airbag fix.

If you're not in really cold weather the dealer didn't update it.

[MKZ7]

Have a 2011 MKZ hybrid (100k miles) and have been noticing a drop in mileage of 15% since the starter battery was replaced 12/18.  I mentioned this to the dealer who replaced spark plugs and filters saying this would fix the problem.  Not!  Mileage continued to fall from 40+ to 35.  It was not until websites like this one and talking to a mechanic friend that I learned about a Ford Tech Service Bulletin (20-2142) that addresses this exact problem of the bcem and pcm modules reprogramming.  Took the car back in and asked the dealer to check this TSB and surprise! the problem was fixed.  The car runs in EV mode again....almost like new.i  Ford was definitely negligent in not reprogramming those modules that was clearly stated in their own TSB..  Love the car, but shame on Ford for not being proactive and needing an owner to uncover the fix for the problem!

[murphy]

The dealer is not Ford.  He is an independent businessman. The dealer wanted to sell you a new car rather than fix your old one.

[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.

 

[Skoli95]

After searching online regarding this issue, I am excited that I found an answer.  Thank you for all who posted.  I will be scheduling a visit to my dealer to get the TSB done.

[Ffhybridowner]

I took my 2012 fusion to the dealer with the tsb202142 (that they never heard about) for the Reduced electric vehicle Operation . They say they reset the pcm and becm. When i got the vehicle back it was like new again. But sadly it didn't stick. A day later it was back to not staying in ev mode. Anyone else that has taken their car to the dealership for this have this problem or did it work for you?

[lolder]

It's possible the car is in a HVB re-conditioning mode that had been inhibited by the glitch. That causes the ICE to run for about 20 minutes and charge the HVB to over full. It then reverts to normal 50% level. The reconditioning mode requires the ICE to run for a period of time. If you turn the car off before it's complete it will initiate it again next time. Indication that it's reconditioning is charging the HVB to the top and staying there with the ICE continuing to run. If it's not that the dealer didn't do it right so take it back.

Edited February 19, 2021 by lolder

[Skoli95]

I finally got my car in to a dealer about 3 weeks ago for the TSB.  They never heard of it, but I gave them a copy from here.  They did the update and only charged me $50.  It definitely fixed the issue and dramatically increase my MPG. Cold weather delayed seeing the best results, but know it is like new. 

[MeeLee]

Thankfully my FFH will never reach 10 years. It barely will reach 2 years doing ride sharing, that is, if I can do this accident free.

I'm putting on roughly 70-90k miles a year.

[Kreg]

We had the no EV problem on a 2010 FFH and the dealer did the FSB 20-2142 fix after I showed it to them. 
EV works now but only at low mph and not for very long. However, it seems to be improving. We’re thinking the cells were ‘off’ for several months and need to be regenerated and balanced and the car is making headway, albeit slowly. Anybody else having poor HVB performance after FSB 20-2142. 

[jcs]

How do I know if I have the EV issue everyone is discussing?  I took my 2011 FFH with 85K miles to an independent garage as over the past year there is hesitancy when accelerating from a stopped position.   They showed me this TSB (202142A) and told me to take it to a dealer.   I'm guessing this is the problem and hopefully this will fix it.  But people on here are noticing EV changes (?) which I don't think I've ever noticed - unless my hesitant acceleration is a sign of that.  Also, I've never gotten more than 35-36MPG (I live in the mid atlantic with mostly suburban nonhighway driving).  I would LOVE to get above 40MPG!

[Waldo]

The issue is related to the software counting the age of the vehicle, so unless your 2010 Fusion was built in 2015, you'll have the issue.

[SunnyB]

On 2/19/2021 at 5:35 AM, Ffhybridowner said:

I took my 2012 fusion to the dealer with the tsb202142 (that they never heard about) for the Reduced electric vehicle Operation . They say they reset the pcm and becm. When i got the vehicle back it was like new again. But sadly it didn't stick. A day later it was back to not staying in ev mode. Anyone else that has taken their car to the dealership for this have this problem or did it work for you?

I still had the problem after a dealer supposedly did the update.  So I took it to a second dealer who confirmed that the update was done.  I still have low mileage and, in addition, for some reason, the car only takes about 14.5 gallons at fill up instead of 17. 

[MeeLee]

2 hours ago, SunnyB said:

....and, in addition, for some reason, the car only takes about 14.5 gallons at fill up instead of 17. 

17 is dead dry. The fusion got a good 50+ miles on reserve (100 miles in some cases).

I think they took the regular gasoline fusion's reserve 25-50miles, and with the hybrid system this means you'll have more reserve.

I never let the fuel go under 100 miles range indicated, even if I still have 200 miles of actual driving range left.

[Hybrid King]

Good day,I'm having the same problem with my 2010 fusion hybrid, have 96, 000 miles but not operating on EV mileage is in the low 20,so I cannot find this new programing you talk about, can you guide me in the right area so that I can print it out to take it to the dealership. Thank you

[Mark JM]

On 10/16/2021 at 1:11 PM, Hybrid King said:

Good day,I'm having the same problem with my 2010 fusion hybrid, have 96, 000 miles but not operating on EV mileage is in the low 20,so I cannot find this new programing you talk about, can you guide me in the right area so that I can print it out to take it to the dealership. Thank you

Here you go:

https://static.nhtsa.gov/odi/tsbs/2020/MC-10174404-0001.pdf

[rbhuff]

I had a Ford dealer do the TSB update on my 2011 FFH when the EV mode stopped working (10 years after the car was built).  After the update, the car ran in EV mode again. However, exactly 1 year later the problem as returned. I'm hoping to use the Forscan software to check the battery age date soon and see if changing that will fix it. Has anyone else had to change the battery age date after the modules specified in the TSB were updated?  TIA

[ibbanez]

new Hybrid owner, is there a difference in having the dealer do this, vs using FORScan?

[FusionDiffusion]

FYI there is a new customer satisfaction program for this that came out today, the program number is 22G04. You can now have this BECM/PCM update performed free of charge through Sept 30, 2023.  Letters will be sent out in a couple weeks. You are eligible for a refund if you paid to have this performed at a dealer previously, and can provide documentation. I think every owner will want this done.

 

Title: Application Performance Upgrade  22G04 Certain 2010 – 2012 Model Year Fusion / MKZ / Milan Hybrid Vehicles Hybrid Battery Reduced Electric Vehicle Operation BECM and PCM Software Update

 

[PaulGo]

FusionDiffusion, thanks for the update!  Do you have a link where I can find "Application Performance Upgrade  22G04 Certain 2010 – 2012 Model Year Fusion / MKZ / Milan Hybrid Vehicles Hybrid Battery Reduced Electric Vehicle Operation BECM and PCM Software Update" so I can show the dealer.  Fords should have done this when they came out with the update that resolved this problem.  

[PaulGo]

I called my dealer and gave them the CSP #22G04.  They verified it applies to my two 2010 Mercury Milan Hybrids, and I set up an appointment for them to do the work.  The age fix I did two years ago works very well, and I hope I get at least as good hybrid performance after I visit the dealership. 

[Mark JM]

Hey, this is good news. I did mine quite a while ago. Car is due for inspection in November. I'll have them do the update then. Keep us in the loop as to how it goes.

Thanks, Mark JM

[Popsotto]

I had mine done a little over 2 years ago. I remember the service people hadn't heard of the reprogram when I went in.

I wonder if they are required to send out the notices to the original owners...it will depend on how many can send in a receipt if they have one.

Then again you wonder how many never even knew about why their cars started having bad mileage and just sold them.

Edited September 11, 2022 by Popsotto

[PaulGo]

On Wednesday, I had my first 2010 Mercury Milan with the CSP.  To my surprise, they also did the driver's side airbag recall.  So far, the results are excellent, although it's hard to tell the difference between this CSP and the age fix which I did two year ago.  Today I had my other Mercury Milan done, but no driver's side airbag replacement (on order maybe next week).  Both cars have about 55 thousand miles, and the average mileage was slightly over 38mpg during the summer months with the age fix.   

[Mark JM]

Thanks for the reply. So they were able to do their fix regardless that you had run the reset yourself. Good news.