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Replaced the blend door motor and all is well so far.

Got all pass codes. Tried the headlamp idea and that did not work. I moved the temp selector to hot all the way and dialed it back to cold and it worked good. However if I put it on the coldest setting the temperature blend door moved to hot. As long as I keep the selector on anything but the coldest setting the AC works perfect. Probably going to have to replace the control panel and blend door, but we'll see about that later. I am going to run it a while. The headlamp idea probably means there is a grounding issue and the module is using the headlamp wiring for a ground somehow. The car has over 236,000 miles so I should expect something like this.

My 2012 Fusion 2.5L SE started blowing hot from the heater before I backed out of the parking lot. Found if I turn off the engine and restart it blows cold for 15-20 seconds then blows piping hot. I put the gauges on and pressures are all good. The blend door goes from cold to hot for some reason. Restart the engine it blows cold every time. But after 15-20 seconds the blend door moves to hot. I am going to try the headlight thing, the battery disconnect idea, however I will first pull codes and look at the ambient air temp. Will post what I find in a little bit.

Fixed it! Found a fuse in the battery fuse box that was not installed correctly and probably since it was new. It was installed slightly crooked so one leg of the fuse was plugged into one side of the box socket terminal and the other leg of the fuse was only touching the top of the fuse box terminal. It must have been that way for a while because of the dust on the fuse leg. Vibration from the vehicle over time caused the fuse to back out completely. That is why the light was going on and off then finally on all the time. Still could not get Forscan to recognize the body control module to reset the battery monitor. However I set a new profile in Forscan and chose Sync #2 and got the GEM module which might reset the battery, but I did not see it. Doesn't matter. The light is off and now I am on to fixing code P0420. Who knows...might be already fixed...

I have the ELMconfig adapter and Forscan loaded onto my laptop. Ran the diagnostics, but it looks like I might need to buy the extended license to get the option to reset the battery monitoring system. I am trying again this morning.

I am looking into Forscan. I have a code reader, but has only a few live scan PIDs. Looks like Forscan is worth getting setup with. I have let the car sit overnight locked and it still comes on. Stays on all the time now. I tested the battery and the alternator myself and is holding about 14 volts under load at 2000 rpm. I had Autozone test the battery and no issues there. I wiggle tested the wiring and the light would go off and on but cannot nail down a location for the issue. I purchased a Motorcraft alternator 3-pin connector from Rock Auto for $28. Will try that and see. This only started after I replaced the alternator, so it is something I did.

I have over 230,000 miles on my 2012 Fusion 2.5. I thought I would replace the alternator since a lot of them go out around 200,000 miles. Bought a brand new Remy alternator from Rockauto. It works great, but after about 1200 miles the battery light came on for a while, then goes off. One night after a rain the battery light came on, headlights flicker and the Advancetac light came on and disabled. Restarted the engine and all returned to normal. Battery and alternator test good at 14.10 volts under load whether the battery light is on or not. Tested both when light is on and light is off. The voltage is the same under load. Under no load the voltage goes no higher than 14.8. The battery is an Autozone Gold $175 new 8 months ago. I put the old alternator back on and still have the same problem. Wiggle tested everything, checked grounds. On a dry hot Texas day the light stayed off all the way to work 45 minutes. Then came back on sometime on the way home. Before I give in and send it to the dealer, I am wondering if anyone has had this problem and what worked for them. I read a few posts on this site and still wondering if anyone has seen this and what they did to fix it.