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

[PaulGo]

2 hours ago, Mark JM said:

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

Yes, both cars were updated and are getting great gas mileage.

[MeeLee]

I got a 2019 ffh, with 105k miles on the odo, and the range got down by 50%, mpg down from 45-48mpg to 41-42mpg.

[Jayberham]

I just got the notice in the mail today to schedule the 22G04 software update, but I had already done the age fix about 2 years ago. Will getting the software update help efficiency or performance any further? Or does it not matter now. Don’t want the hassle of dropping off car to dealership if it doesn’t provide any further benefit.

[William LaPlante]

I have a 2011 FFH with 154,000 miles.  The hybrid function has been bogging down for a couple of months now.  Got a notice of an "Application Performance Upgrade 22G04" yesterday.  This has been a great car for me, but I am afraid to drive over long distances (2 hours plus drive).  Hopping this software gets me back to what has been a great car!

Edited September 28, 2022 by William LaPlante

[William LaPlante]

Left message to Tasca Ford in Seekonk, Ma.  Waiting for a reply.

[SunnyB]

I went to the Ford dealer under the 22G04 program, but they did nothing since the PCM and BECM had already been updated more than a year ago.  I told them there was still a problem with reduced EV-only mode performance even after the software update was done, but they refused to diagnose the problem saying that the 22G04 program only covered the software update. 

 

When people refer to the "age fix" is that something different than the software update?  Is it putting in a false battery age date to "trick" the software into using the battery.  

 

Maybe I have a bad hybrid battery that won't regenerate.  Is the Ford dealer the only one who is going to have the equipment necessary to test the hybrid battery?

[snodeel@cox.net]

I also thank you for the update. I have a 2012 FFH with 105,000 mi.. The battery reset was done 2 months ago with FORscan which helped a lot. I got the 22G04 notice and was concerned about going in for the update.  Sounds like it is ok and may offer additional improvement.

[Mark JM]

I just scheduled my 2010 for inspection the 1st week of November, going to have them also do the update. I did the Forscan thing quite a while ago, car has been great. This update hopefully should continue that

[snodeel@cox.net]

Thanks Mark,

I just set my oil change and update for 10/12/2022. I will advise what I find out and any change in performance.

[snodeel@cox.net]

As promised I am updating my experience with the Ford Motor Co. update on the BECM and PCM on my 2012 Ford Fusion hybrid. My ford has about 105,000 miles on it and I bought it used around 2 years ago. I had seen the mpg decrease steadily until I did the FORscan BECM reset a few months ago.  After that I saw moderate improvement to performance and mpg. 

On 10/12/2022 I took my car into a local dealership here in the Phoenix area of Arizona for the free update. 

WOW what a difference!   I am very impressed.  No mention was made of the battery age reset I had done. I took the Ford out for about a 30 mile freeway drive at 65 mph on cruise control and by the time I got home the mpg was still increasing.  I parked the car with 38.2 mpg for the freeway.  I have also driven it around neighborhoods and am watching it run on electric up to around 40 mph. So far so great! I should note that on the freeway I used the AC sparingly and had no passengers.

 

Edited October 14, 2022 by snodeel@cox.net

[Mark JM]

Excellent, thanks for the update

[bryanb]

On 10/4/2022 at 8:08 AM, SunnyB said:

I went to the Ford dealer under the 22G04 program, but they did nothing since the PCM and BECM had already been updated more than a year ago.  I told them there was still a problem with reduced EV-only mode performance even after the software update was done, but they refused to diagnose the problem saying that the 22G04 program only covered the software update. 

 

When people refer to the "age fix" is that something different than the software update?  Is it putting in a false battery age date to "trick" the software into using the battery.  

 

Maybe I have a bad hybrid battery that won't regenerate.  Is the Ford dealer the only one who is going to have the equipment necessary to test the hybrid battery?

 

the age fix is something different.  this involves a computer (likely laptop) special software (people mention FORscan), and a special interface plug to car.  Which I did, as well as the TSB in Aug 2020.  Been averaging 35-36 since.  Got the letter about the Performance Upgrade.  I paid for the TSB be done in 2020, which was a software update for the PCM, and BECM.  I originally called the dealer about the refund that the recent letter mentioned, but he also let me know there was an outstanding recall for airbags.  So went in for both.  Upon arrival, the service manager mentioned that of Ford 'reopened' the issue, there is another update.

 

Ended up not charging me for anything, nor refunding anything.  But he did check my headlight bulbs I couldn't get to last weekend, without taking the front bumper off (yes it comes off to replace the bulbs. I tried without, and didn't get to one bulb) for no charge.

 

It is my suspicion that the TSB and the Performance Upgrade letter may be the same update.  The former, the customer would pay for; its not a recall.  the later is an offer from Ford to take care of a problem before it becomes a recall, or fix a problem that doesn't require a recall.

 

But this is my question: to confirm my suspicion, is the TSB and the Performance Upgrade the same software update?

[SunnyB]

23 hours ago, bryanb said:

 

But this is my question: to confirm my suspicion, is the TSB and the Performance Upgrade the same software update?

 

It is the same software update.

 

Didn't help my car, I can only assume the hybrid battery in my car is not working right.  And if that is so, the age fix workaround won't fix it.

[Mark JM]

Car went in the Nov 1st for inspection and the program update. Everything went well, car is working and running well, as before. Also had them pull the bottom plastic engine shield, had a couple of rusted stuck bolts,  and replace all the hardware securing it, just in case I need to fully remove it, usually just removing the oil filter cover piece is all I take off. Excellent work from the dealer.

[AndrewC]

Thank you everyone for your information on here.  I have a 2017 C-Max Energi, so it’s only about 60 months old.  It is, however, throwing a P0B24 code (Hybrid Battery “A” Voltage Unstable).  Dealer is replacing the BECM under the warranty as I’m at ~158,000km.  From there we’ll see if it fixes the problem as I only have about 2k km of warranty left.

 

Does anyone know if Ford put better firmware on cars after the 2012 model year?  Or, why does this technical bulletin only apply to 2010-2012 model years?  I wonder what will happen to 2013 vehicles once they hit 10 years, or 100 months, or whatever the magic number was.

[MeeLee]

My personal battery issue went away when I replaced the 12v battery with a lithium one.

 

Still ironing out some kinks.

 

Also, do ecvt oil change at 100k miles!

 

Third, make sure your tires are highest psi (45-50psi hot, or 40-45psi cold). To compensate for road noise, I installed a tire that had a 2" larger oitside diameter, but you can find 1" larger outside diameter as well.

[Rita]

On 5/17/2020 at 8:57 PM, Matt said:

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 .

 

On 4/28/2020 at 7:33 PM, billford said:

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.pdfUnavailable

 

Hello, can anyone help me locate a diagram and/or the location of the wiring harness. 

 

https://www.fordpartsgiant.com/parts/ford-wire-asy_ce5z-14a411-a.html

 

My husband had the car (Milan Hybrid 2010) (We also have a 2011, not issues thus far) diagnosed and they said that's what the issue is.  My husband is determined to fix and replace it himself, are there any issues with high voltage electrocution? 

 

Thanks...Rita

[Rita]

On 4/28/2020 at 7:33 PM, billford said:

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 284.91 kB · 92 downloads

 Can some help me locate a diagram or explain where the wiring harness is located?

 

https://www.fordpartsgiant.com/parts/ford-wire-asy_ce5z-14a411-a.html

 

My husband had the car (2010 hybrid Milan) diagnosed, that is the issue, per the TSB; he is determined to fix it but needs to a diagram of the location.  He has been to three different dealerships and they will not help him.

 

My question, is there potential of electric shock while replacing this part?

 

Thanks for any help provided!!

[Rita]

On 5/5/2020 at 9:32 PM, fun4u said:

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.

 

Hello...would you happen to still have the contact information, and procedure for the Chairman's Office.  I just tried calling "customer service", they wouldn't give me the information.  We have two hybrid's, the 2010 is down, 2011, not issues yet, thank goodness.