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

[MikeJ]

I can not get the Forscan 2.3.36 software to work as I keep getting an error That states  movefile code 5, access denied. I disabled my Webroot and virus stuff and it still does it HELP.

UPDATE!  After working on this it is Webroot doing this so you turn it off and install and to let it run you either turn webroot off or set it to monitor. Still waiting for my Forscan approval and then I can fix my car.

Edited November 4, 2020 by MikeJ

[MikeJ]

OK somebody HELP I got my entry from the Russians(haha) And went to set up my 2 month trial and all my damn computer wants to do is open it adobe and it can't! So what do I do because right now I would rate this a minus 10 because it has been a PITA. 

[MikeJ]

I figured it out it is an issue with windows 10

[nationalwheel]

2010 Fusion Hybrid 105500 miles, I just did this today. 5 mins to do, immediate results soon as light turned white to green, using empowered display. I just bought this car for my wife, the previous owner mentioned nothing about ev function maybe not working. Maybe didn't know? I had asked him about the battery, he said it had been checked and was good. I got a great deal on this vehicle, original owner well maintained, all records. I already own a 2010 Fusion SEL bought new. I love both of these vehicles, only owned the hybrid for a couple of weeks. Thanks to Allen84 for the great write up. I had already used the forscan program to diagnose a bad evap temp sensor in the ac system of my SEL so am somewhat familiar with the operation of it. Thanks again.

[DenverPed]

National wheel, You will be shocked at your gas mileage compared to your SEL. I can very easily get 50MPG on mine and my overall long term mileage since the “fix” is well over 40MPG. My wife no longer can drive much so I do most the driving. It only takes a little attention using Empower to maximize your mileage. I am an original owner and I am at 165K.

[Glenoid]

Give Allen84 some cash. This fix has saved me $1000 over the last year !!!

[FFHinVA]

Hybrid EV mode works again! Success at the dealer!

 

Had similar lack of EV capability on my 2010 FFH (111K miles) that everyone is describing starting about a year ago. Tried everything including the battery rebalance at the dealer back in 2019. I also started having a "wrench" light and the "Stop Safely Now (SSN)" triangle occurring.

I was going to try myself (via allen884 directions - And thanks to allen884 for taking the time to publish!) the battery clock set back, but needed a Windows10 laptop, got sidetracked,  etc. , and didn't get around to it.

(I did install the FORScan lite on my android phone, but this doesn't allow any changes to be made to the software).

 

But then the urgency increased due to the SSN triangle. I also saw where the TSB 20-2142 (attached) came out in April 2020 to correct the EV issue. Also, TSB 11-7-31 was already out there since 2011 which addresses the wrench issue, and I wasn't sure if it was done on my car. And, interestingly enough, the dealer wasn't familiar with  the TSB. Just thought the batteries were getting old.

So I decided to get everything checked and hopefully done. 

 

In summary (For $262, 20Nov2020)…
5 modules were re-programmed: BECM, PCM, IPC, BCM,TCM
Performed BMS reset and Adaptive Strategies reset.
TSBs 11-7-31 and 20-2142 reviewed and applied/conducted (through re programs).

 

And now I'm back to 42mpg in town, and can get up to 30-40 mph on electric again (within 20 mins of leaving the dealer).

 

Also,  I complained to Ford  in 2019 about the EV loss, under case# 17514618, and I received no notification about the TSB being released. Nothing, at all.

 

No wrenches or triangles yet either, but time will tell on those. 

 

TSB 20 2142 for reduced EV mode MC-10174404-0001.pdf

Edited November 24, 2020 by FFHinVA

[DPB]

I have an issue on my 2011 fusion with 150,000 miles that seems to be along the same lines.

 

As soon as I remove my foot from the brake the engine starts. The battery is nearly always at 100%. I still get great mileage in the high 30's on the highway, but it has dropped to about 30 in town (due to the reduction in EV operation). It used to be closer to 40 around town. The engine cuts out as I slow with my foot on the brake but restarts as I come to a full stop, then if I press the brake down far enough it shuts down again. 

 

I brought it to one dealer and he said I need a new battery (which I doubt). I tried another Ford dealer and specifically asked to reset the battery age, which they did for $35 and It did work, but only  for for 1 day. Now I am back to the same condition. However on that day, it functioned as it had for the past 9 years. I was able to go an average long distance in EV mode at 30-35 MPH on a level road (miles) and the battery declined in a way that seemed about the same as it always had to me.  That would seem to indicate to me that the battery is fine. 

 

I just downloaded  Forscan and obtained my activation code and created my free members account with these excellent instructions. I am waiting for my OBD II device and will give this a shot and report back.

[mirak]

Quick update: It's now been a little over 6 months and 7k miles since applying the fix. The hybrid tech is still functioning perfectly. I've had this car for over 11 years and 150k miles and it still drives like new (post fix).

[mirak]

1 hour ago, DPB said:

I have an issue on my 2011 fusion with 150,000 miles that seems to be along the same lines.

 

As soon as I remove my foot from the brake the engine starts. The battery is nearly always at 100%. I still get great mileage in the high 30's on the highway, but it has dropped to about 30 in town (due to the reduction in EV operation). It used to be closer to 40 around town. The engine cuts out as I slow with my foot on the brake but restarts as I come to a full stop, then if I press the brake down far enough it shuts down again. 

 

I brought it to one dealer and he said I need a new battery (which I doubt). I tried another Ford dealer and specifically asked to reset the battery age, which they did for $35 and It did work, but only  for for 1 day. Now I am back to the same condition. However on that day, it functioned as it had for the past 9 years. I was able to go an average long distance in EV mode at 30-35 MPH on a level road (miles) and the battery declined in a way that seemed about the same as it always had to me.  That would seem to indicate to me that the battery is fine. 

 

I just downloaded  Forscan and obtained my activation code and created my free members account with these excellent instructions. I am waiting for my OBD II device and will give this a shot and report back.

 

I suspect the dealer didn't properly reset the age. Either that or you really do have a problem with the battery. The fix should work long-term. Let us know what you find out. Good luck.

[DPB]

1 hour ago, mirak said:

 

I suspect the dealer didn't properly reset the age. Either that or you really do have a problem with the battery. The fix should work long-term. Let us know what you find out. Good luck.

I just talked to the dealer and they asked me to bring the car back so they can perform TSB 20-2142. On the last service call, they only reset the battery age back a few years (at my request) and  as I said that only worked for a day (which is odd).  The battery seems fine during the course of that day the EV mode was operating as normal, around town, below 40 MPH it was running fine on EV and the battery discharged at it's normal rate. 

[xns916]

4 hours ago, DPB said:

I have an issue on my 2011 fusion with 150,000 miles that seems to be along the same lines.

 

As soon as I remove my foot from the brake the engine starts. The battery is nearly always at 100%. I still get great mileage in the high 30's on the highway, but it has dropped to about 30 in town (due to the reduction in EV operation). It used to be closer to 40 around town. The engine cuts out as I slow with my foot on the brake but restarts as I come to a full stop, then if I press the brake down far enough it shuts down again. 

 

I brought it to one dealer and he said I need a new battery (which I doubt). I tried another Ford dealer and specifically asked to reset the battery age, which they did for $35 and It did work, but only  for for 1 day. Now I am back to the same condition. However on that day, it functioned as it had for the past 9 years. I was able to go an average long distance in EV mode at 30-35 MPH on a level road (miles) and the battery declined in a way that seemed about the same as it always had to me.  That would seem to indicate to me that the battery is fine. 

 

I just downloaded  Forscan and obtained my activation code and created my free members account with these excellent instructions. I am waiting for my OBD II device and will give this a shot and report back.

I'm in the same boat, but I did the reset myself via these instructions in the city my MPG is 30 mpg so it's basically back to the same it was before the fix, the fix only lasted about a month or two

[lolder]

Some have had trouble resetting the age. Proof that it's been successful is re-accessing the proper page and seeing that the HVB age has been reset. Even ifthe age has been reset the weather is getting colder and mileage goes down then. Cycling every 1/2mile of EV mode at around 30 mph is normal operation after car is warm. HVB SOC should hover around the 50% mark. These are also reasons the ICE may run:

 

1: Low HVB
2: HVB reconditioning ( 2010-12 )
3: Evaporative emmissions check at start up
4: Speed over 46-62-86 mph depending on model and software.
5: Higher power demand such as acceleration
6: Cabin heater demand
7: Warmup of catalytic converter when cold and speed above 12 mph. ( 2010-12 )
8: Use of "L" gear

[DPB]

On 11/25/2020 at 12:48 PM, xns916 said:

I'm in the same boat, but I did the reset myself via these instructions in the city my MPG is 30 mpg so it's basically back to the same it was before the fix, the fix only lasted about a month or two

I just went to the dealer and had them do TSB 20-2142 and the cars is back to as it was new. 

[Pear17]

I wanted to apply this fix myself but unfortunately I couldn't get my old Surface Pro to detect the OBD2. I went to the ford dealership to ask them to apply to the TSB 20-2142 fix but they insisted on charging me for diagnosis and expected to have my car for a few days and a few hundred dollars in "software update" charges.

 

Bought a laptop off craigslist and did this in 10 minutes. Haven't driven much yet, but the difference between the electric and ICE was immediately noticeable. Big thanks to Allen84 for this easy to follow guide.

 

If anyone in the Dallas area needs help, feel free to reach out.

[rbhuff]

I just wanted to let everyone know that my 2011 Ford Fusion Hybrid was experiencing the same issue. (The hybrid battery just turned 10.) Thanks to your help, I found TSB 20-2142. After calling 4 different local Ford service departments, I finally found one that would cover the fix under the emissions warranty. I just picked up the car after they updated the BECM and PCM. It appears to have fixed the problem. Thanks again.

[CDJ]

On 11/4/2019 at 6:02 AM, asicking said:

It’s all in the original post to which you are commenting. Every detail, every step; it’s all there. This link should take you to it:  https://www.fordfusionforum.com/topic/19361-my-instructions-on-restoring-the-hybrid-ev-function-on-the-ford-fusion-hybrid-approaching-the-89-years-mark/

 

Link doesn’t work on here anymore. Can you repost?

[CDJ]

On 11/5/2019 at 9:58 AM, NormB said:

Allen84 Rocks! Allen helped me reset the hybrid battery back to year 1 and bingo, the car runs like new again. I have a 2010 Fusion with 196K and the EV issues started in the fall 2018. Last winter was a gas-guzzling nightmare with the engine constantly revving and the EV battery constantly charged/charging (that was worrisome) except during continuous highway driving. I brought my car to Erinwood Ford in Mississauga twice - they also had the Service Manager drive it home over night, and after all this time and cost, I was advised "conditions are normal". Clearly they were not, but since the vehicle did not generate error codes, these guys can't fix what they cannot diagnose. I contacted Ford Canada on several occasions with zero help. In fact, I also notified them of the potential fix posted online and that is when all communication ended - Ford simply stopped responding to my emails. Less than 10 minutes with Allen and all is now back to normal driving. Nothing lasts forever, but it is obvious that continuously charging a fully charged battery and over revving an engine is not the way to mitigate safety concerns, so I challenge any claims that this fix compromises operational safety. It is simply planned obsolesce or a programming error. Either way Ford should 'fess up and rebuild customer trust. In the meantime... A BIG THANK YOU TO ALLEN84!

Can you post the instructions? The link doesn’t seem to bring up the post any longer

[jebrice406]

Same here. Can you share the instructions?  Is this something I can do with Forscan on my own or do I need to go to a dealer to get TSB 20-2142 done?

[rbhuff]

I went to a dealer to get the TSB done. Luckily, I found a dealer who would do it for free under they emissions system warranty. Otherwise, I would have followed these instructions:

 

 

 

[md40022]

I just bought a 2010 Fusion Hybrid with 113k miles. The price was very good, but right off the bat I had the issue with it very rarely going into EV Mode. I already have the OBDLink on order from Amazon and will be putting that fix in to play within the next few days, but as a brand new Fusion Hybrid owner I have a few questions on this issue. Maybe I'm overthinking this, but can anyone put me at ease on the following points....

 

1.  Is there any chance that Ford set the HVB to specifically stop entering EV mode at 9 years or so, knowing that because of the battery's age that if it kept going into EV mode at the same frequency as it did when newer that the battery was going to completely dump-out in the very near future?  And to clarify what I mean by that, let's say that by Ford setting the HVB to very rarely enter into EV mode once it reached 9 years of age they are allowing that battery to last for 20 years (as an example) by kind of "conserving it" in its old age. As where if we perform this reset maybe it seems wonderful and we are happy to have EV mode back in the short term, but then maybe the HVB ends up going completely dead a year after this reset.  I guess what I'm wondering is are we all sacrificing a 20 year life on the HFB for the short term sake of milking an extra 6 months of EV Mode?  I would love for someone who is smarter than I am to put my mind at ease with this haha

 

2. In the event that the HVB were to totally dump out at some point, is the car still fully operable on a day-to-day basis via the ICE or is the car non-op until the HVB is replaced? I've tried to search for an answer to this and there seems to be all sorts of conflicting opinions on this.

 

A big thanks to Allen for this incredible info that he shared with everyone, I just want to make sure that I'm doing the right thing before putting the fix into play within the next few days.

Edited January 31, 2021 by md40022

[Spirit10]

I know nothing official.  If you are worried, have Ford apply the official TSB.  As for me, I have a 2010 Milan (the Mercury version of your Fusion) and did the fix almost exactly one year ago (before Ford came up with a fix) and have seen no side effects, it just restored the operation back to being able to use the battery whereas without the fix, it only ran on the ICE.  I don't know when the battery may become truly useless, but mine is working pretty much like it did back in 2010 when we bought the car new.  I really can't tell a difference from a few years ago, and the car ran great until the age limit was hit and bam it didn't. Then zap the age and bam, it works again.  FWIW

[DenverPed]

My experience is exactly like Spirit10. 14 months since I did the “Fix”. Running like the day I bought it. 40 MPG! 

[lolder]

The 2010-12 FFH has 207 d-cell NiMH cells in series. If a cell fails open circuit the car will not move. I have not heard of any of those failures. If it fails closed-circuit the HVB only loses a small percent of it's power/capacity. The US DOE did tests on two FFHs and found they had lost only 8% capacity after 160 k miles. Ford said the HVB should last the life of the car. I would not worry about the HVB. If at 15 years you have to replace the HVB for 3-4k it would be acceptable if the ICE is still OK and no rust. The principal cause of breakdown is throttle body sticking which leaves you at idle throttle and limp home mode. You can clean or replace them yourself for about $200. 

 

Read this thread: https://fordfusionhybridforum.com/topic/13744-limp-mode-2010-ff-hybrid-code-p1aoc/?tab=comments#comment-112921

Edited February 1, 2021 by lolder

[md40022]

Thanks for that response. I only stumbled upon this thread within the last day or two and didn't get to read ALLLLL 16 pages of responses until just now. Seeing that Ford put out a tech bulletin on this makes me feel much better about doing the battery life reset.

 

I was worried that we were all going rogue by putting this fix into play and all of the short term benefit that we gained would be lost a year down the road when we'd all have dead HVBs and would be ranting and raving on here. So for Ford to acknowledge the issue and the fix via a tech bulletin makes me feel better. I don't think they'd do that if they foresaw resetting the battery life as a potential problem in the making.

 

Really good info here from everyone. In the week or two that I've had the car, I really love it. The funny thing is the only disappointment that I've had up to this point was that I was only getting maybe 23 to 25 mpg. It wasn't that big of a deal to me though because I wasn't specifically looking for a Hybrid gas-saver when I bought this car, it only happened that way because the price was right. But as I began to notice that EV mode veryyyyy rarely ever was used that's what made me start to research, and low and behold.... 

 

I've already got ForScan downloaded and if Amazon delivers my OBDLink today then I'll hopefully as good as new by end of day.