My instructions on restoring the hybrid EV function on the Ford Fusion Hybrid approaching the 8/9+ years mark.

[Wil]

Just reset my our 2010 Fusion Hybrid with 68K miles and the fix works!  I used Windows 10 in BootCamp on a 2017 Macbook Pro using MacOS Catalina.

 

There are two things one has to do to get the suggested bbfy Pro OBD II adapter to work on a Mac and that is to use the Apple "white" USB to USB C adapter as off market adapters will not allow for max baud rate which is necessary for the computer and FORScan to recognized the car.  The fix only takes a few minutes once the OBD adapter is recognized.  I download the ODB device drivers but manual says they may be included in the Windows OS but I did not check for them.  

[allen84]

On 1/19/2020 at 9:00 PM, Jackson16 said:

I have 2010 Ford Fusion Hybrid when I go over 70mph the Orang wrench comes on ! And when I shut  the engine off goes away ! No check engine light no codes pending . Anyone has the someone problem! 

 

 

Do you lose power from the engine when it happens?  Where you can't maintain the acceleration speed past 40 mph?  The yellow wrench problem may likely be your throttle body.  It's a $70 part at the dealership. You can replace this part yourself (youtube video will assist you on that. I did it myself, pretty easy to do) Otherwise a shop can replace it for you for a couple of hundred dollars I believe.

 

Yellow wrench won't give a code, as turning the car off and on clears the problem temporarily until it eventually displays double yellow wrench.  If you keep ignoring it, a check engine light will finally show up. That is when you can stick your ODBII to find out what the code is (I think mine finally showed up after the 10th time?) My trouble code was P2112 (throttle actuator stuck closed)

The next thing you can do is remove and clean throttle body part, with throttle body spray cleaner that you can buy https://www.amazon.com/CRC-05078-Throttle-Air-Intake-Cleaner/dp/B000M8PYO2

 

You have to be very careful cleaning the part, as the flap controlling the open and closed position is delicate. Also, don't get your finger(s) caught in the flap, it will hurt a lot. This may or may not fix it. For some people it did, and have no problems. Mine only lasted a week after cleaning it, but I was a bit rough on it while cleaning it, as it was really caked with thick black carbon. I Was scrubbing it off with a toothbrush and scraping off the carbon with a popsicle stick. That was when I just replaced the part entirely since it was kinda cheap.

Edited January 22, 2020 by allen84

[allen84]

18 hours ago, prdobson said:

Allen,  I am interested in having you walk me through the reset process. I have ordered the odb2 device from amazon (delivery last week of January) and have a windows lap top, but being old and  dyslectic  I have a terrible time reading and following your excellent  procedure for resetting the clock.  I find the thought of messing with  my Hybrid terrifying  for fear that I might  do real damage with a slip up.  The Ford service department near me called yesterday and said they will fix my car as soon at the Ford Motor Co engineers tell them what to do.  This has been going on since my 2010 Hybrid stopped being a hybrid and I have little faith  that their fix will come any time soon.

 

I can help you.  I can also may very well help you perform the procedure while you sit back and watch.   I just need remote access to your computer.  You need to download the software called Anydesk or Teamviewer so I can take temporary control of your computer as if I was there.  The program is free when you choose to install it as personal use.

 

All you would need to do is, park as close to your house, preferably inside the garage, so the wifi signal to your laptop is the strongest, as I would need a stable internet connection to you to stay connected.   Once the ODBII is recognized to your laptop and the Forscan software is ready to use (I can help you with getting that program when I remote access to you if you have trouble getting it activated).   

 

PM me your number, and we agree on a time we can do this.   Once we agree on a time that's best for us, we just text back and forth or use whatsapp for video calling, this will avoid long-distance phone call charges.

[allen84]

18 hours ago, Milan_OH said:

 

Yes, shipping across the border is a show-stopper.   If the demand is there, I could facilitate assembling the kit & shipping.  

 

If it's something you want to pursue as a side hustle, go right ahead lol.  Whatever payment you receive from helping people, it's yours to keep. You have my blessing.   

 

There probably isn't much demand, as the cost of shipping back and forth would be more than the cost of the ODBII, where one can buy one and keep it in their possession for any future use, an invaluable tool to have for diagnosing check engine lights for other problems.  Procuring a laptop for short time use, shouldn't be too difficult.  There has to be someone, anyone should know that will own one.  It's an asset owned by many people, just as much as owning a cell phone.  You also have to deal with the constant of shipping the laptop where you will run the eventual chance the laptop may get damaged through transit, and lending a stranger a laptop will need a high degree of trust to make sure you get it back.

Edited January 22, 2020 by allen84

[Acoustasonic13]

Allen,

 

Wow! Just picked up my new to me 2010 FFH with 60K miles. Symptoms just as everyone described. Engine running 99% of the time. Purchased all that was required ahead of time in anticipation of needing to have this done. Followed the easy instructions, and was done in 10 minutes. Was able to pull out of my driveway and up the street to nearly 35mph under battery power before the engine kicked in. Battery and engine engagement swapping as necessary for the rest of my test ride around town. Love it!

Thank you for posting this thread and helping so many with this issue.

 

TJ

Edited January 22, 2020 by Acoustasonic13

[prdobson]

Thanks Allen for your offer of help.  I have downloaded the software and have the device from Amazon and after playing with my computer and watching your great step by step procedure hundreds of times, I have gained enough confidence to attempt to reset my clock.  If I run into a block I will seek your advice.  Again Thanks!  

[eric66]

Hi Allen,

    Thanks for the great write-up. Restored the EV function on my daughter's 2011 FFH. Now on to the ABS problem!!

 

Cheers,

Eric

[prdobson]

I need help Allen or anyone.  I followed all the steps and when i entered "BECM module configuration" and pressed play I  received a notice that an Extended License was required and would not let me continue.  What am I doing wrong ?

[prdobson]

When I took my Hybrid in for the reset by Ford, could they have put a block into the system to prevent me from resetting the clock?  

[bangster]

23 minutes ago, prdobson said:

I need help Allen or anyone.  I followed all the steps and when i entered "BECM module configuration" and pressed play I  received a notice that an Extended License was required and would not let me continue.  What am I doing wrong ?

You need to request a free short term extended license from Forscan (there also longer term pay options). You also need to apply it to the program.

 

https://forscan.org/forum/viewtopic.php?f=5&t=836

Edited January 24, 2020 by bangster

[allen84]

2 hours ago, prdobson said:

I need help Allen or anyone.  I followed all the steps and when i entered "BECM module configuration" and pressed play I  received a notice that an Extended License was required and would not let me continue.  What am I doing wrong ?

 

I'm my instructions on the first page, I linked a YouTube video on how to get a free trial of the forscan program. You need to get the 2 month free trial to get full functionality of the program. After that's done, you will have no further issues. 

 

If you have trouble getting the 2 month trial, I can make the key and email you the license key, as I can create them.  You can also create them too, once you join as a free member on their forum.  But you have to wait an hour or so, once the moderator approves.   I will email you the key after I'm done work later tonight. 

Edited January 24, 2020 by allen84

[prdobson]

Well after 6 hours of tons of errors my car is back to its old self...up to my daughter's house and back 100%on EV!!!

The first error was getting Standard instead of Extended License which I found out when I got an error message. Then I deleted the program from the laptop thinking I could install a new Extended license, but it would not let me get a new license with the same e-mail address . So I got out the old laptop and paid for a one year Extended License  and went back out to the car and it said there were no drivers for the OBD11 (the windows 10 was automatic).  it took an hour to install drivers on the old Vista windows.  In the mean time I tried everything to install an Extended License on the new laptop and for some reason the program would not load, I even tried to turn off my Security system...no download possible. When I plugged in everything with the old laptop, the thing turned off for low battery.  I turned on the hybrid and plugged in the laptop in the 120 volt outlet in the back seat.  It took 10 seconds for the reset and I am now a very happy camper 

[allen84]

@prdobson I'm glad you were able to do it.   The Forscan program you downloaded comes as Standard.   You didn't have to delete the app at all.   All you had to do was generate the Free trial 2 month extended license which was free.  I guess you didn't sign up as a forum member over there then.  That was the part you missed.    Being a (free) forum member would give you the ability to generate the license key, free.   Once you generated the license key, it is a small file that would be downloaded.  You take that key file and load it into the Forscan program, and it will be activated for 2 months free extended.   It was all explained in the video.   

 

I could have also made the key for you, and emailed it to you as I mentioned before.

 

 

But I'm happy if you're happy that you got your EV back. 

Edited January 25, 2020 by allen84

[PaulGo]

With Ford Motor Company having financial difficulties and a possible bankruptcy I wonder how much resources  they are devoting to coming up with a fix to the problem they have acknowledged for our hybrids.

Why Bankruptcy Is a Forgone Conclusion for Ford Motor Company

https://www.ccn.com/why-bankruptcy-forgone-conclusion-for-ford-motor-company/

[bangster]

If it is out of warranty or they can weasel out of fixing it, they really no longer care unless it is something widespread like the DPS6 transmission. Selling parts and labor is a money maker for them, but not as much as a new vehicle. fixing customer concerns and goodwill really get them no further ahead, they know your voice means little.

[Ann Arbor Ford citizen]

All along I had been blaming Michigan winters for poor performance of the HVB lately.  Hmmph.

 

allen84's procedure worked to perfection.  (Move to the USA, man, and run for office!!)  I have my beloved Hybrid back.  My first winter drive today?  46.6mpg (after averaging 32 since November).  

 

The local Ford dealership had not been helpful.   Apparently they have a dozen people who brought their cars in for the same reason, and they just passed the concerns up to Ford HQ "waiting to hear back".  I shared the link to this thread and got no response.

 

If anyone in the Ann Arbor MI area wants to restore their HVB battery using allen84's procedure, I can do it for them for free- just reply to this post.  It's easy, takes a few minutes.  I have the laptop and the connector device.  I'll feel really good about lowering carbon emissions by helping a few more drivers turn their cars into hybrids again.  So just let me know.

[MMHOwner2010]

Guys, you should check if you're in a CARB state.  I'm in NY and the NYS DEC told me my car has a 10 year hybrid battery warranty.  Its the same in California, and probably a few other states that adopted their rules.  If you are you should definitely bring your car to your dealers to have the issue documented, and you should file complaints with the state if you're unable to have it fixed by Ford.  The issue needs more pressure on Ford.  Your dealer should not be charging you for diagnosing an under-warranty defective component.

 

My dealer documented that I need a new hybrid battery, and Ford refuses to authorize a replacement because of the "investigation" that they apparently feel they can pretend they're doing forever.  I've filed a complaint with the NYS attorney general's office.

 

I think the next step really should be a class action suit if we can't obtain satisfaction.  I know I plan to keep pushing the issue between the AG office, Ford Motor Co, and my dealership for about another month or so before I start to seek out a legal path.  There's no way that it is a coincidence that this starts failing right after the federal warranty expires.  There weren't many 2010s produced, but I think if this starts happening to 2011s this year it should reach a big enough class for a lawyer to take interest...

[bangster]

There were more 2010 Hybrids (36k over 2009 and 2010) than 2011 and 2012 combined (2011 - 11k, 2012 - 14k).

[lolder]

3 hours ago, MMHOwner2010 said:

Guys, you should check if you're in a CARB state.  I'm in NY and the NYS DEC told me my car has a 10 year hybrid battery warranty.  Its the same in California, and probably a few other states that adopted their rules.  If you are you should definitely bring your car to your dealers to have the issue documented, and you should file complaints with the state if you're unable to have it fixed by Ford.  The issue needs more pressure on Ford.  Your dealer should not be charging you for diagnosing an under-warranty defective component.

 

My dealer documented that I need a new hybrid battery, and Ford refuses to authorize a replacement because of the "investigation" that they apparently feel they can pretend they're doing forever.  I've filed a complaint with the NYS attorney general's office.

 

I think the next step really should be a class action suit if we can't obtain satisfaction.  I know I plan to keep pushing the issue between the AG office, Ford Motor Co, and my dealership for about another month or so before I start to seek out a legal path.  There's no way that it is a coincidence that this starts failing right after the federal warranty expires.  There weren't many 2010s produced, but I think if this starts happening to 2011s this year it should reach a big enough class for a lawyer to take interest...

You don't need a new HVB, just the software fix in this thread. There were a total of about 70,000 nearly identicle Ford, Lincoln and Mercury  hybrids produced from 2010-12. Models before and after were different.

[MMHOwner2010]

The dealer seems to think I do.  Has the fix worked for everyone with the issue?  Has anyone relapsed after? Is it going to work for the remainder of the life of the car?  I'd rather not have it "fixed" and blow my warranty (by having it functional the remainder of the period) only to have it relapse after the warranty has lapsed..

 

I think if the fix is really the fix, then why hasn't Ford agreed with it? Why "investigate" instead of just reprogram the battery age at minimal cost to all parties?

 

We know the theoretical degradation was about 4%, but whats the actual degradation we're all experiencing?  IIRC early Prius models had to have batteries replaced, and we're using similar chemistry to those.

[lolder]

The Ford HVB chemistry is not the same as the early Prii. Some of the Prius HVBs had corrosion problems on the connections. Most of not all the fixes here have worked. Some testing of Prius showed >60% capacity decline at 160k miles but performance was unaffected. Don't believe the dealer about a new HVB.

[capetownkg]

On 1/29/2020 at 3:39 PM, MMHOwner2010 said:

Guys, you should check if you're in a CARB state.  I'm in NY and the NYS DEC told me my car has a 10 year hybrid battery warranty.  Its the same in California, and probably a few other states that adopted their rules.  If you are you should definitely bring your car to your dealers to have the issue documented, and you should file complaints with the state if you're unable to have it fixed by Ford.  The issue needs more pressure on Ford.  Your dealer should not be charging you for diagnosing an under-warranty defective component.

 

My dealer documented that I need a new hybrid battery, and Ford refuses to authorize a replacement because of the "investigation" that they apparently feel they can pretend they're doing forever.  I've filed a complaint with the NYS attorney general's office.

 

I think the next step really should be a class action suit if we can't obtain satisfaction.  I know I plan to keep pushing the issue between the AG office, Ford Motor Co, and my dealership for about another month or so before I start to seek out a legal path.  There's no way that it is a coincidence that this starts failing right after the federal warranty expires.  There weren't many 2010s produced, but I think if this starts happening to 2011s this year it should reach a big enough class for a lawyer to take interest...

I agree that a class action is needed, and let me know where to sign up or add my experience.  I am going today to pick mine up from a Ford dealer who is saying my battery is bad and quoted me at 8k to fix.  Obviously my car isn't worth that and I plan on doing "the fix" myself.

 

The short info I looked up showed roughly 54k hybrid vehicles from the 2010-2012 that could be affected. At the prices quoted they could stand to make a lot of money.  It's just way to coincidental that this is happening after the warranty is up.  And don't try and tell me it's the cycling of the batteries when we have people who have 60k miles having the same issue as people with 200k.

[capetownkg]

Just picked it up. Read the write up they gave me. Ford is well aware of this. "This is normal characteristics due to age of battery". Cause yeah when I bought this they said you have a 10 year hybrid car after that it's a gas vehicle! Lol what a joke. Last Ford I have that's for sure

[akirby]

Don't confuse a dealer with Ford.   Ford doesn't own dealerships nor do they control what the dealerships tell you.  Dealers don't want to be liable if something happens.

 

Remember this platform was retired in 2012 and Ford can't make this type of change without doing some investigation as to why it was set that way in the first place and to make sure changing it won't cause other issues now or down the road.  That's not always easy to do on an older platform that's been out of production for 8 years.   Can you imagine the s**t storm if they made the change and a year from now all 2010 hybrids stopped running altogether?  I'm sure it's being worked but probably doesn't have a high priority.

[lolder]

8 hours ago, akirby said:

Don't confuse a dealer with Ford.   Ford doesn't own dealerships nor do they control what the dealerships tell you.  Dealers don't want to be liable if something happens.

 

Remember this platform was retired in 2012 and Ford can't make this type of change without doing some investigation as to why it was set that way in the first place and to make sure changing it won't cause other issues now or down the road.  That's not always easy to do on an older platform that's been out of production for 8 years.   Can you imagine the s**t storm if they made the change and a year from now all 2010 hybrids stopped running altogether?  I'm sure it's being worked but probably doesn't have a high priority.

All true but I can't remember of even one incident in over 10 years on several forums of a HVB failing open-circuit which is the only failure mode that stops the car from driving. The D.O.E. 160k mile test showed only an 8% capacity loss. Another problem with the software limitation is the HVB stops equalizing which is probably worse than using an old HVB normally and might actually hasten an open-circuit failure. Keeping the ICE running except when stopped is not a strategy to preclude a "Dead On the Road" event. The HVB always has to start the ICE and that load is probably the same as the ~20 kw  used while driving. I've never seen that figure but it spins up the ICE to  1000+  rpm in .4 seconds. The way these NiMH HVBs are cycled should make these batteries last indefinitely long. Most of these cars are out of warranty now except in some CARB states. i don't expect Ford to do the right thing here and I would definitely recommend everyone do this software fix even if it makes the car quit at 15 years. Aftermarket HVBs are available for ~$3.5K, far less than $8k from Ford.

Edited February 1, 2020 by lolder