Sync Programming (G0000176)

Publication date: 2023-05-25
Reference number: G0000176
Supersedes refnos: 19-7047, 20-7078, 21-7088, 23-7035

SYNC PROGRAMMING

TECHNICAL SERVICE BULLETIN

Reference Number(s): 23-7035, Date of Issue: May 25, 2023

FORD:

All Models

Superceded Bulletin(s): 21-7088, Date of Issue: May 25, 2023

NOTE: This bulletin supersedes 21-7088.

SUMMARY

This article supersedes GSB 21-7088 to update the vehicle model years affected and the Service Information.

The APIM may require programming to add system enhancements/upgrades, improve system reliability and/or address consumer issues. The following information is intended to help determine when programming is necessary and address common programming issues using the FDRS.

SERVICE INFORMATION

When Is APIM Programming Necessary?

PMI is required with any APIM replacement. Each replacement module comes with the latest software.

Upgrades and service messages - updates to resolve performance issues or upgrades to include Android Auto and Apple CarPlay, any applicable SSM, TSB or GSB.

NOTE: Gen2 equipped hybrid vehicle powertrain modules require the latest software in order to download the latest AEIM-SYNC software.

APIM Configuration programming app is an FDRS option. When a concern is present with the APIM as-built data, DTC U2100 or U2101 is set in the APIM, the configuration programming option can be used. Server corrections may be required prior to programming the module again. If SYNC has latest software installed, standard programming performs the same function as APIM configuration programming.

NOTE: Some vehicles may have a standard APIM programming option in FDRS only while others have an software update option. The software update option only downloads the latest available software. Once the update completes successfully, the FDRS removes it from the software update list.

APIM PROGRAMMING TIPS USING FDRS PROGRAMMING

Prior to performing any APIM programming, confirm SYNC function by pressing the phone button on the steering wheel or on the instrument panel. If no SYNC function is present, the APIM will not program. Follow normal WSM diagnostics.

Refer to WSM, Section 418-01 - General Procedures - Module Programming or Section 415-00 - General Procedures - SYNC Module Programming for detailed programming steps.

NOTE: For vehicles that now use FDRS programming, continue with starting a vehicle session using the FDRS scan toolGo to the Toolbox Tab > Select APIM > Choose the appropriate APIM programming procedure PMI, Module Replacement Programming, or Standard Programming will be available.

It is recommended to install a battery charger when performing programming steps. Low/poor battery voltage during APIM programming will induce various SYNC, center display screen, or Bluetooth related concerns. Make sure the battery charger is set to maintain 12.8v-13.5v. Confirm the BCM 12v battery SOC percent is greater than 80%. Lower than usual SOC % will affect module programming and APIM programming. Low SOC % will activate the battery management system message disabling the audio system or activate deep sleep mode.

A hard-wired internet connection is strongly recommended. If a hard-wired internet connection is not available, higher speed Wi-Fi connections are strongly recommended. Using a slower Wi-Fi source will result in programming errors. Recommend using Mobile Hotspot as needed when internet provider connections issues are suspected. Refer to programming error chart below.

Make sure the proper SYNC USB 2.0 A-Male to A-Male cable and SYNC USB 2.0 A-Female to Mini B Female 5-pin adaptor is being used for SYNC Gen1 and Gen2. This is recommended for APIM replacement programming and APIM/CIP programming.

EFFECTS OF NOT HAVING AN APIM PROGRAMMED PROPERLY

Future map updates will cause errors and will not complete.
Missing features such as climate, various settings for vehicle, and SiriusXM.
Inaccurate navigation or compass.
Connected Services may not work properly such as incomplete software updates via Over-the-Air, Connected Navigation inoperable, and enhanced voice recognition failures.
Applink, FordPass or Lincoln Way features may not operate properly.
Loss of navigation, navigation voice prompts, or SYNC voice prompts.
Erratic Apple CarPlay and/or Android Auto operation.
General inability for SYNC to communicate to the Ford back-end cloud.

USB DRIVE SIZE

For SYNC 4 vehicles, a 64GB or larger USB 3.0+ flash drive is required for APIM software update. The USB drive must be formatted to exFAT. Using a smaller drive such as a 16GB flash drive or incorrectly formatted drive will induce SYNC programming issues potentially resulting in APIM failure.

For SYNC 3 vehicles, recommended size for the USB drive is 32GB or larger. The USB drive must be formatted to exFAT. Using a 16GB, 8GB, 4GB, or incorrectly formatted flash drive will induce SYNC programming issues potentially resulting in APIM failure.

For Gen 2 SYNC equipped vehicles, recommended size for the USB drive is 16GB. The USB drive must be formatted to FAT32. Using a 4GB, 8GB, or incorrectly formatted flash drive will induce SYNC programming issues potentially resulting in APIM failure.

USB FLASH DRIVE FORMATTING

Make sure the USB flash drive being used is formatted correctly. To see the available drives, hold down the Windows icon keyboard key and press the E keyboard key. Right click on the USB flash drive and select Properties. If File System under the General tab is not exFAT, the drive must be formatted to exFAT for SYNC 3 and SYNC 4 systems only. If File System under the General tab is not FAT32, the drive must be formatted to FAT32 for Gen 2 systems only.

To format the USB flash drive, right click on the USB flash drive, select Format, select exFAT for the File System, and select Default Allocation Size for the Allocation Unit Size. Do not de-selecting Quick Format as it will result in a lengthier operation. To fully format the drive, de-select Quick Format and continue.

NOTE: Full format can take up to 15 minutes to complete.

NOTE: If all normal WSM, TSB, SSM and/or GSB diagnostics have been performed, there may be a SYNC server issue preventing SYNC programming. If all above diagnostics, as well as all below diagnostics, have been performed, it may be necessary to contact the Ford TAC to restore the SYNC server information.

WINDOWS 10/11 (HIDDEN FILES)

In order to access the SYNC cache folder, the hidden files function needs to be enabled:

Use the magnifying glass in the bottom left hand corner of the Windows bar, search for This PC. This will show the This PC application.
Select the application and a new window will open titled This PC. Select the View tab at the top of this window.
Find the Hidden Items check box at the upper right corner of the window and check the box. This will show hidden files.

SYNC CACHE FOLDER

Press the Windows Key located in lower left hand corner of the keyboard. Select This PC (or My Computer) > C: Drive > Program Data > Ford Motor Company > SYNC > Cache.

SYNC/APIM REBOOT-RESET PROCEDURE (GEN 1 SYNC, GEN 2 SYNC, AND SYNC 3)

The SYNC reset/reboot procedure is performed by pressing and holding the seek forward/seek up button (> >) while pressing and holding the radio power button located on the center display screen. Release both buttons after 3-4 seconds and allow the reset to complete.

SYNC/APIM REBOOT-RESET PROCEDURE (SYNC 4)

Vehicles equipped with a volume/power and right seek button, press and hold both the volume/power and right seek button for 10 seconds and the system will reboot. For vehicles not equipped with a volume/power button, holding the seek right and volume down buttons on the steering wheel controls will reboot the SYNC 4 system.

FDRS APIM - RESET SYNC MODULE OPTION (AVAILABLE FOR SOME VEHICLES)

Start vehicle session using the FDRS scan tool > Go to the Toolbox Tab > Select APIM > APIM - Reset the SYNC Module.

NOTE: An APIM/SYNC reset/reboot consists of an APIM software cold boot. It may not be necessary to perform a master reset after performing a cold boot if the concern is resolved. The SYNC reset/reboot procedure does not remove or delete any stored user information that occurs when performing an APIM master reset.

NOTE: The flash drive full format method can take up to 10 minutes for completion. This method is recommended to ensure all bad files are completely removed from the flash/USB drive used.

RVC REQUIREMENTS

Refer to the Components Requiring A Repair Validation Code form located on PTS homepage - Technical Assistance dropdown. SYNC 3 and newer generations of SYNC requires an RVC only using the FDRS. An RVC is no longer for required for any Gen 1 or Gen 2 SYNC equipped vehicle. When attempting to manually generate an RVC, a message displays stating The RVC Assistance Form Is Not Available For This Vehicle And Market. Contacting Technical Assistance is not required.

APIM Programming Concerns or Issues After APIM Replacement - SYNC 4 Equipped Vehicles

Error State/Message	Possible Causes	Solution
Procedure Unsuccessful -ValidateFlashActionDIDsAgainstModule/ Procedure Unsuccessful -GetConfigDataFromGIVIS Modified Configuration data is missing from Ford server/GetVehicleNodeInfo Direct configuration data is missing. Procedure Unsuccessful -UpdateSoftwareOverUSB Unable to program module, process aborted Procedure Unsuccessful -GetFilesForPMI Exception getting flash action part numbers Unable to Obtain Software Binary File Blank screen after APIM programming Center display screen stays on after programming attempt. Stays on with ignition off	USB update was unsuccessful APIM data missing on server APIM Programming tab closed during PMI or software update Backend APIM data error APIM Programming tab closed during PMI or software update. Battery voltage, configuration issue APIM is in programming mode. Programming was stopped or was not completed.	Retry SYNC programming Contact TAC for assistance. Follow FDRS directions. Check SOC per the directions above. Perform network test and confirm APIM pass. APIM reset, APIM configuration programming, confirm screen operates.

APIM Programming Concerns or Issues After APIM Replacement - SYNC 3 Equipped Vehicles

Error State/Message	Possible Causes	Solution
Repeat MEM ERR, LST ERR, PKG ERR, INSTL ERR, or VER ERR Replacement APIM with MEM_ERR, LST_ERR, PKG_ERR, INSTL_ERR, or VER_ERR Invalid Software/Incompatible Hardware Data Corrupted, ErrorReturn, GetVehicleNodeInfo Direct configuration data is missing, or Error during programming Reduced, incorrect, or half screen display/FDIM after programming	Incorrect USB format, faulty USB flash drive, or SYNC software concern with the original module Concern with the replacement module Replacement APIM is incorrect for the vehicle APIM. data missing from the server. Incorrect APIM data on the server Customer modified APIM data using aftermarket tool. Incorrect APIM data.	Perform a master reset and retry programming or try Universal USB Updater method to update SYNC. Replacement required for either repeat error message. (SIGN_ERR - redownload files, retry programming). Contact the TAC Select On-line 1878 at the bottom of PTS after entering the VIN. If replacement module is correct, contact TAC for assistance.
Procedure Unsuccessful -MainUpdateProcess Failed to restore module configuration Procedure Unsuccessful - FlashSoftware Failed to flash ** 14*_ Procedure Unsuccessful - FlashSoftware CHECK VALID APP FAIL	APIM data missing from the server. Incorrect APIM data on the server. Backend APIM data error/part number software doesn't match database	Contact the TAC to have server corrections made
WARNING: Applications are currently not loaded - follow Custom programming and select the current assembly indicated by the check marks current on SYNC page.	Applications missing from the SYNC server or missing from the SYNC page USB drive was not re-inserted into the scan tool when prompted at the end of the SYNC programming	Start FDRS session. Perform a network test to update the SYNC server and refresh the SYNC page. Contact the TAC to have server corrections made.
Update does not start automatically when inserting the USB into the vehicle and 5 minutes have elapsed.	USB not properly formatted Downloaded files are still compressed (double zipped) The autoinstall.lst file is missing from the US.B drive	Verify operation of the USB port using the MIT Verify 32GB USB drive is properly formatted to exFAT Verify the autoinstall.lst file is present on the USB drive Verify all downloaded files are extracted/decompressed Access the USB drive, open the SyncMyRide Folder and Autolnstall File to confirm gz Archive file (tar.gz.) is displayed Full format the flash drive and retry the SYNC programming
Select/No/Flash, blank SYNC page, or MainUpdateProcess Failed	Poor internet connection Missing SYNC software on the server. SYNC software flashing concern	Use an alternate internet source and retry the SYNC programming Contact the TAC to have server corrections made
Module stuck in bezel diagnostics mode	Concern occurred during programming or software update attempt Non-responsive center display screen	Perform SYNC reboot by pressing and hold the power button with the seek forward (if equipped) up to 10 seconds Perform the APIM configuration programming using FDRS Follow WSM, Section 415-00 for not responsive to touch
Unable to find\USB Disk\VIN.lst	The autoinstall.lst file is missing from the USB drive Downloaded files are still compressed (double zipped) USB drive not properly formatted Poor internet connection	Verify the autoinstall.lst file is present on the USB drive Attempt an alternate internet source Use a new USB flash drive and verify formatting Access the USB drive, open the SyncMyRide Folder and Autolnstall file to confirm gz Archive file (tar.gz.) is displayed Full format flash drive properly, and retry SYNC programming
Repeat message stating Installation In Progress populates after SYNC programming attempt Repeat message stating Voice Recognition Not Ready Center display screen stays on after programming attempt. Stays on with ignition off.	Error occurred during programming or with software update APIM stuck in programming mode or step(s) skipped during programming process APIM is in programming mode. Programming was stopped or was not completed	Perform SYNC reboot according to this article, APIM master reset, turn off automatic updates. Complete APIM configuration programming or standard programming without any applications selected. Perform SYNC reboot according to this article 2x, APIM master reset, and complete APIM programming again Check SOC. Attempt PMI or APIM configuration programming and reevaluate.

APIM Programming Concerns or Issues after APIM Replacement - Gen 2 SYNC and Gen 1 SYNC Equipped Vehicles

Error State/Message	Possible Causes	Solution
Screen display Module Is Not Provisioned after programming the replacement APIM. (Gen 2 SYNC) Center display screen stays on after programming attempt. Stays on with ignition off.	Applications were not installed on the new module using the USB flash drive Service Provisioning app was not selected during PMI-Module Replacement programming (FDRS) APIM is in programming mode. Programming was stopped or was not completed.	Format 16GB or 32GB USB drive to FAT32. Retry APIM programming Perform standard programming to add factory equipped applications Open FDRS and click on PMI or CIP. Select the application titled BT4T-14D546-DA (service provisioning only select when a new module is installed). Complete the APIM programming and retest. Check SOC. Attempt PMI or APIM configuration programming and reevaluate.
Wireless provisioning is not functional or Wireless Access Points is displayed on the center display screen. (Gen 2 SYNC)	Wireless Provisioning button was selected during provisioning. This is for in-plant use only.	Wait approximately 40 minutes KOEO. The APIM will deactivate the wireless provisioning automatically. An APIM soft reset or power reset will not reset or alter the internal timer.
Provisioning Error (Gen 2)	Partially zipped/compressed SYNC files on the USB drive Faulted USB drive Incorrect CIP files SYNC server concern	Verify all downloaded SYNC files are extracted/decompressed Use a different USB drive Perform PMI and select Force CIP (FDRS) Contact the Ford TAC to have corrections made
Data Corrupt, GetVehicleNodeInfo Error, or StatusCode: 500 Error VM-PB-E07-Unable to resolve Variant ID during APIM programming (Gen 2 SYNC and Gen 1 SYNC)	APIM data missing from server. Incorrect APIM data on server.	Contact the TAC to have server corrections made
Module stuck in bezel diagnostics mode Sirius Not Equipped after programming. Gen 1 SYNC equipped with center display screen.	Concern occurred during programming or software update attempt. Configuration concern with APIM, ACM, or FCDIM	Perform SYNC reboot by pressing and hold the power button with seek forward (if equipped) up to 10 seconds Format 16GB or 32GB USB drive to FAT32 only. Perform PMI and select Force CIP (FDRS) As-built programming FCDIM and ACM. Standard or configuration APIM programming and retest
Applications Desktop Error during or after SYNC update. (Gen 2 SYNC)	Occurred during software update Outdated or faulty SD card causing indexing issue	Format flash drive to FAT32 then proceed with standard APIM programming Remove SD card and perform SYNC reboot. If error is resolved, SD card replacement is required
Center display screen response/calibration. (Gen 2 Only)	Center display screen not calibrated Configuration error during APIM programming	Configure touchscreen per general procedures in WSM, Section 415-00 Perform Force CIP (FDRS) and click on the Touchscreen Calibration option
Any of the following messages: Unsupported/Corrupt Device/Installation Has Run Out Of Space/Does Not Work With This Version	Master reset not performed prior to the attempted installation of software Standard programming performed while APIM is already at the latest level; applications are attempted to be installed twice	Perform an APIM master reset as per the appropriate WSM, Section 415-00 (Gen 2) Perform standard APIM programming (FDRS)
Invalid or unsigned file -your package may have corrupted, the package signature may have failed or the signature may have been revoked	The Global Navigation Application requires a second, hidden application to be loaded in the background during APIM programming. (SYNC Gen 2 MyTouch)	Perform standard APIM programming per the appropriate WSM, Section 415-00; only select App To Correct Modules That Report Null ESN. Complete APIM programming. Perform Standard APIM programming again and only select Global Navigation Application and complete APIM programming
Select/noPreinstallRestore -unable to program replacement APIM. (Gen 1 SYNC)	Incorrect APIM installed Updating from v1 APIM to v2 APIM to support 911 Assist Incorrect vehicle data on the SYNC server	Verify the correct APIM is installed Make sure the RCM and IPC are updated to latest software level to support 911 Assist with v2 replacement APIM, retry APIM Programming Contact the TAC if the correct module is installed
VIP/CIP missing on the SYNC page in OASIS BEV VIP/CIP software installed in a non-BEV vehicle. (Gen 1/Gen 2)	Information was not uploaded to the SYNC database Hybrid powertrain modules not updated (PCM, BECM, DCDC, ACCM, SOBDM, TCM/SOBDMC) Incorrect VIP/CIP software installed	Perform the Read VIN and DTC function. If missing still, contact the TAC to have corrections made. Reprogram the hybrid powertrain modules and retry SYNC programming (as directed in FSA) Contact the TAC to have corrections made
Install ActiveSync, ActiveSync Is Present message (Gen 1 and Gen 2)	Incorrect APIM is installed SYNC server data is incorrect Turn off/disable-ActiveSync	Select On-line 1878 at the bottom of PTS after entering the VIN. If the replacement module is correct, contact TAC for assistance. Disable active SYNC and retry SYNC programming

Map Software Updating/Map Software Errors - Gen 1, Gen 2, Sync 3

Error State/Message	Possible Causes	Solution
Installation Error. (SYNC 3) Message stating SYNC Must Be Updated Before This Map Update Can Be Applied. Please Remove The USB DriveVER_ERR01-06 (SYNC3)	Error with map software or SYNC 3 software installed Attempting to add update map software with outdated SYNC software (v2.2 or earlier) USB/drive connected to USB port after update completed	Perform an APIM master reset as per the appropriate WSM, Section 415-00, turn off automatic updates, and attempt the map software update again Complete standard programming to update SYNC software and attempt maps software update again Contact CRC or refer to the Owner's Manual for the map supplier to receive a new USB/drive that contains updated map software
Installation Failed: BGMAP ERR01-05. (SYNC 3)	USB/drive connected to the USB port after update completed Map software/hardware has incorrect version Concern with map software/hardware installed on USB/drive Vehicle is not equipped with navigation	Perform an APIM master reset as per the appropriate WSM, Section 415-00, turn off automatic updates, and attempt the map software update again Contact CRC or refer to the Owner's Manual for the map supplier to receive a new USB/drive that contains updated map software Verify the vehicle was built with navigation from the factory
Installation Failed: (SYNC 3)	USB/drive connected to USB port after update completed Incorrect USB format or concern with the USB flash drive USB connection interrupted SYNC or USB/drive storage limitation Corrupted software/hardware installed on USB/drive	Format or full format the 32GB USB drive to ExFAT, re-download map software per the navigation site or receive a new USB drive Perform APIM master reset, turn off automatic updates, retry software update, leave USB connected to the USB port for at least 5 minutes Replace the map software USB drive again
Navigation voice stopped after map software update. Message stating Installation In Progress populates after SYNC programming or map software update (stay on after programming).	Error occurred with map software or with SYNC 3 software installed Error occurred during software update, APIM stuck in programming mode	Perform SYNC reboot according to this article, APIM master reset, turn off automatic updates, and complete standard programming without any applications selected Perform SYNC reboot according to this article 2x, APIM master reset, and complete standard programming without any applications selected
Navigation missing after programming or module replacement (Gen 2) SD card concern after replacement. (Gen 2)	Nav app EA5T-14F657-AG wasn't selected during programming (Gen 2) Vehicle not built with navigation (Gen 2) Outdated SYNC software Concern with SD card	Confirm vehicle was built with navigation (Gen 2) Perform Force CIP (FDRS) standard programming, select correct Nav app 14F657 and retest. (Gen 2). Then proceed installing latest v3.10. Replace SD card as needed. (Gen 2).

FDRS Programming Issue

Error State/Message	Possible Causes	Solution
One of the following messages: Application has ended in an error state Application request to Ford server. The application has not been able to retrieve data from the Ford server. Please report this to the technical hotline.	Poor internet connection Missing SYNC software on server	Use an alternate internet source Attempt APIM configuration programming/check APIM ESN in vehicle and compare to ESN on the SYNC page
FDRS states Module Has Been Replaced during software update while original APIM is installed	32GB or 64GB USB drive incorrectly formatted APIM was replaced	Contact the TAC to have corrections made Format 32GB flash drive to ExFAT and retry SYNC programming
FDRS states Vehicle Data Missing, APIM Programming Options Missing, or Data Unavailable	FDRS database concern. Missing information from FDRS database.	Contact the TAC. A SYNC server concern is not the root cause.
Corrupt USB tool detected	Outdated version of the desktop tool being used to update thumb drives Missing file from the universal USB tool	Make sure that the desktop application being used is 1.0.2.8 or higher Update the universal USB thumb drive with the updated desktop application and it will resolve any missing files
USB tool inserted provided no indication of programming on the screen	Vehicle in transport mode Master reset was performed before USB was inserted without a key cycle Missing file in the universal USB thumb drive	Make sure that the desktop application being used is 1.0.2.8 or higher Update the universal USB thumb drive with the updated desktop application and it will resolve any missing files Verify that the vehicle is out of transport mode Shut the vehicle off, open the door, restart the vehicle, verify that SYNC is fully booted and reinsert the USB thumb drive
Incompatible SYNC version indicated on the screen	Universal USB updater was overwritten by a different process such as FDRS, map update or consumer website update	Make sure that the desktop application being used is 1.0.2.8 or higher Update the universal USB thumb drive with the updated desktop application and it will resolve any missing files

NOTE: This information is not intended to replace or supersede any warranty, parts and service policy, workshop manual (WSM) procedures or technical training or wiring diagram information.