TSB 22-2404 - Revised TSB for Stuck USB Updates

[Mach-Lee]

We have an updated TSB for fixing issues getting USB updates to work when updating with FDRS. This bulletin supersedes TSB 22-2150 (AKA the fix for stuck Power-Up 1.7.1 update). The TSB now mentions the possibility of stuck GWM USB update being caused by this issue as well (in addition to APIM and TCU). There are also additional warnings related to the APIM being permanently locked out when this procedure is used incorrectly, and a couple of additional figures showing how the USB adapters should be connected together. The previous TSB also showed the wrong trim panel being removed from the F150.

I want to emphasize Module Update Repair in FDRS should be used with caution. Both @Mike G and myself have seen dozens of vehicles where dealers ran Module Update Repair unsuccessfully and ended up permanently locking the APIM (SYNC) module so that it can never be updated again. In most cases, it seems they tried to run the procedure without having the required USB adapters connected, or ran it too many times. There is a 20-day countdown timer that starts the first time Module Update Repair is run (see bold blue caution statement below). If the procedure is not completed successfully in that initial 20-day window, or run more than 15 times, the APIM will be permanently locked, and the only way to fix it is to completely replace the APIM. Because so many dealers have accidentally "bricked" APIMs running this procedure unsuccessfully, APIMs are currently on a multiple-month backorder.

TECHNICAL SERVICE BULLETIN 22-2404 31 October 2022
Unable To Update The APIM, TCU Or GWM With The FDRS And USB Drive - Module Recovery

This bulletin supersedes 22-2150.

Models:

2021 Bronco
2021 Edge
2021 F-150
2021 Mustang Mach-E
2021 Nautilus

Summary

This article supersedes TSB 22-2150 to update the Service Procedure.

Issue: For some 2021 Mustang Mach-E, F-150, Edge, Nautilus and Bronco vehicles technicians may experience the inability to update the accessory protocol interface module (APIM), telematics control unit (TCU) or gateway module (GWM) using the Ford Diagnosis and Repair System (FDRS) and Universal Serial Bus (USB) drive. The PTS – OTA Dashboard on vehicles with this condition may also display multiple APIM and/or TCU updates have failed, and/or a no OTA history message. In addition, on vehicles with this condition, the customer may have reported experiencing a Ford Power-Up software update failure message via the vehicle display and/or FordPass/LincolnWay. This may be due to an internal software error. To correct this condition, follow the Service Procedure to update and/or recover the APIM/TCU.

NOTE: Only 10% of vehicles may require this procedure.

Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:

• 2021 Mustang Mach-E/F-150/Edge/Nautilus/Bronco
• Inability to update the APIM, TCU or GWM using the FDRS and USB drive

Special Tool(s)

USB-to-Ethernet adapter: Trendnet TU2-ET100 USB2.0, Trendnet TU3-ETG USB 3.0, Startech USB31000S USB 3.0, UGREEN USB USB 3.0 model no 40321, Amazon Basics USB 3.0 U3-GE-1P. These adapters have been validated through Ford service testing.

Mini B 5 Pin Female Adapter: Rotunda Part# CCMUSB-AF-BF5 or equivalent (Vehicles with USB Media Hub)

USB 2 Cable - Male to Male: Rotunda Part# CCMUSB2-AM-AM-10 or equivalent (All vehicles)

Ethernet cable assembly, obtain locally (All vehicles)

NOTE: Ford has received feedback from technicians that the following USB-to-Ethernet adapters do not work and should not be used: TP-Link USB3 - 10/100/1000, Cable Creations 10/100/1000 USB3, UGREEN USB2 - 10/100, Cable Leader USB 2.0, UGREEN ‎FBA_20256. In the near future, a list of good/bad USB-to-Ethernet adapters will be published on PTS > Service Tips.

Service Procedure

CAUTION: Due to Ford cyber security requirements, the module repair procedure outlined in this article is limited to a maximum of 15 attempts with a total of 20 days from the first time the application is run before the application is permanently disabled for each unique VIN. Make sure that all required and compatible tooling listed in this article is available prior to performing this procedure to reduce the chances of encountering this lockout state. If a lockout occurs, module replacement may be necessary. Note that even if the application is run successfully, the 20 day timer (allowing 15 attempts) continue to run in the background. If the module repair application has successfully completed in the past, it is not required to be run again.

NOTE: Administrative access on the laptop computer being used is required to perform this procedure. Make sure any antivirus software loaded in the laptop computer is disabled or uninstalled prior to performing this procedure.

NOTE: Use only a wireless connection for internet access as this application requires the use of the laptop computer ethernet port during the module recovery procedure. Verify the FDRS is at the latest software level.

See attached PDF for full procedue and pictures:

 

[Mach-Lee]

In most cases, the dealers inadvertently locked the APIM update process many months ago while doing BlueCruise updates (21G01). When the APIM update wasn't working, they just haphazardly ran Module Update Repair without realizing it requires the USB adapters, and unknowingly started the 20-day lockout countdown (they probably didn't read the TSB at all). The dealer likely never came back with the USB adapters in the 20-day window, and just returned the car to the customer without working BlueCruise after giving up. As a result, there may be hundreds or even thousands of 2021 Mach-E's with locked APIMs that will no longer receive APIM updates, which may impact the functionality of BlueCruise. Dealers will need to order and replace the APIM to fix this. Some people have been waiting 2-3 months for a replacement APIM in their quest to get working BlueCruise.

If you got Power-Up 3.5.3 or 22-PU0707-SCH-POPB installed recently you should be okay. The version numbers are below if you check on the SYNC screen:
Version: 22177_PRODUCT
Revision: 473
Version: 22228_PRODUCT
Revision: 539

If you have a SYNC version that starts with 21XXX, you should contact your dealer with this TSB as you probably have an issue receiving SYNC updates.

 

[SnBGC]

Wow.
A software time bomb inadvertently activated by the dealer (or home FDRS user).
Terrifying.

I guess we know why some people are getting the 3.5.x updates and still no changes to the location of the A/C button or Alexa etc. Stunning news.

 

[generaltso]

A software time bomb inadvertently activated by the dealer (or home FDRS user).
Terrifying.

I don't think there have been any reports of this being activated by a home user.

 

[Mach-Lee]

I don't think there have been any reports of this being activated by a home user.

Yeah, self-updaters are going to read the directions and have the USB adapters because they don’t want to do anything wrong. It’s been the dealers causing problems.

Greg, there are several 3.5.x updates and the A/C button doesn’t change until you get 3.5.3.

 

[Blue highway]

We have an updated TSB for fixing issues getting USB updates to work when updating with FDRS. This bulletin supersedes TSB 22-2150 (AKA the fix for stuck Power-Up 1.7.1 update). The TSB now mentions the possibility of stuck GWM USB update being caused by this issue as well (in addition to APIM and TCU). There are also additional warnings related to the APIM being permanently locked out when this procedure is used incorrectly, and a couple of additional figures showing how the USB adapters should be connected together. The previous TSB also showed the wrong trim panel being removed from the F150.

I want to emphasize Module Update Repair in FDRS should be used with caution. Both @Mike G and myself have seen dozens of vehicles where dealers ran Module Update Repair unsuccessfully and ended up permanently locking the APIM (SYNC) module so that it can never be updated again. In most cases, it seems they tried to run the procedure without having the required USB adapters connected, or ran it too many times. There is a 20-day countdown timer that starts the first time Module Update Repair is run (see bold blue caution statement below). If the procedure is not completed successfully in that initial 20-day window, or run more than 15 times, the APIM will be permanently locked, and the only way to fix it is to completely replace the APIM. Because so many dealers have accidentally "bricked" APIMs running this procedure unsuccessfully, APIMs are currently on a multiple-month backorder.

TECHNICAL SERVICE BULLETIN 22-2404 31 October 2022
Unable To Update The APIM, TCU Or GWM With The FDRS And USB Drive - Module Recovery

This bulletin supersedes 22-2150.

Models:

2021 Bronco
2021 Edge
2021 F-150
2021 Mustang Mach-E
2021 Nautilus

Summary

This article supersedes TSB 22-2150 to update the Service Procedure.

Issue: For some 2021 Mustang Mach-E, F-150, Edge, Nautilus and Bronco vehicles technicians may experience the inability to update the accessory protocol interface module (APIM), telematics control unit (TCU) or gateway module (GWM) using the Ford Diagnosis and Repair System (FDRS) and Universal Serial Bus (USB) drive. The PTS – OTA Dashboard on vehicles with this condition may also display multiple APIM and/or TCU updates have failed, and/or a no OTA history message. In addition, on vehicles with this condition, the customer may have reported experiencing a Ford Power-Up software update failure message via the vehicle display and/or FordPass/LincolnWay. This may be due to an internal software error. To correct this condition, follow the Service Procedure to update and/or recover the APIM/TCU.

NOTE: Only 10% of vehicles may require this procedure.

Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:

• 2021 Mustang Mach-E/F-150/Edge/Nautilus/Bronco
• Inability to update the APIM, TCU or GWM using the FDRS and USB drive

Special Tool(s)

USB-to-Ethernet adapter: Trendnet TU2-ET100 USB2.0, Trendnet TU3-ETG USB 3.0, Startech USB31000S USB 3.0, UGREEN USB USB 3.0 model no 40321, Amazon Basics USB 3.0 U3-GE-1P. These adapters have been validated through Ford service testing.

Mini B 5 Pin Female Adapter: Rotunda Part# CCMUSB-AF-BF5 or equivalent (Vehicles with USB Media Hub)

USB 2 Cable - Male to Male: Rotunda Part# CCMUSB2-AM-AM-10 or equivalent (All vehicles)

Ethernet cable assembly, obtain locally (All vehicles)

NOTE: Ford has received feedback from technicians that the following USB-to-Ethernet adapters do not work and should not be used: TP-Link USB3 - 10/100/1000, Cable Creations 10/100/1000 USB3, UGREEN USB2 - 10/100, Cable Leader USB 2.0, UGREEN ‎FBA_20256. In the near future, a list of good/bad USB-to-Ethernet adapters will be published on PTS > Service Tips.

Service Procedure

CAUTION: Due to Ford cyber security requirements, the module repair procedure outlined in this article is limited to a maximum of 15 attempts with a total of 20 days from the first time the application is run before the application is permanently disabled for each unique VIN. Make sure that all required and compatible tooling listed in this article is available prior to performing this procedure to reduce the chances of encountering this lockout state. If a lockout occurs, module replacement may be necessary. Note that even if the application is run successfully, the 20 day timer (allowing 15 attempts) continue to run in the background. If the module repair application has successfully completed in the past, it is not required to be run again.

NOTE: Administrative access on the laptop computer being used is required to perform this procedure. Make sure any antivirus software loaded in the laptop computer is disabled or uninstalled prior to performing this procedure.

NOTE: Use only a wireless connection for internet access as this application requires the use of the laptop computer ethernet port during the module recovery procedure. Verify the FDRS is at the latest software level.

See attached PDF for full procedue and pictures:

I'd like to speak with the moron engineer who decided that there is a 20 day 15 try limit before self destruct. Maybe engineering really isn't for them. Perhaps a different line of work.

 

[Logal727]

In most cases, the dealers inadvertently locked the APIM update process many months ago while doing BlueCruise updates (21G01). When the APIM update wasn't working, they just haphazardly ran Module Update Repair without realizing it requires the USB adapters, and unknowingly started the 20-day lockout countdown (they probably didn't read the TSB at all). The dealer likely never came back with the USB adapters in the 20-day window, and just returned the car to the customer without working BlueCruise after giving up. As a result, there may be hundreds or even thousands of 2021 Mach-E's with locked APIMs that will no longer receive APIM updates, which may impact the functionality of BlueCruise. Dealers will need to order and replace the APIM to fix this. Some people have been waiting 2-3 months for a replacement APIM in their quest to get working BlueCruise.

If you got Power-Up 3.5.3 or 22-PU0707-SCH-POPB installed recently you should be okay. The version numbers are below if you check on the SYNC screen:
Version: 22177_PRODUCT
Revision: 473
Version: 22228_PRODUCT
Revision: 539

If you have a SYNC version that starts with 21XXX, you should contact your dealer with this TSB as you probably have an issue receiving SYNC updates.

So you're saying that people had a reasonable suspicion of dealers able to perform BlueCruise updates? I was told it was the owners fault for not getting the updates done and still didn't get OTAs and are SOL. /sarcasm

 

[Logal727]

I'd like to speak with the moron engineer who decided that there is a 20 day 15 try limit before self destruct. Maybe engineering really isn't for them. Perhaps a different line of work.

Seems reasonable to me. Guessing it's the system hackers would need access to the most to find security weaknesses on the vehicle.

 

[Blue highway]

Seems reasonable to me. Guessing it's the system hackers would need access to the most to find security weaknesses on the vehicle.

GWM maybe... APIM? I don't buy that there is a rational logic chain to have it self destruct... sorry.

 

[Logal727]

GWM maybe... APIM? I don't buy that there is a rational logic chain to have it self destruct... sorry.

I guaranteed they've done the math on replacing APIM or the cost on having a security breach.

Look what's happened with Hyundais and Kias getting stolen left and right from a simple security hack in the steering column. Gonna be so many lawsuits. Can't believe they didn't even do a recall for that either.

 

[Blue highway]

I guaranteed they've done the math on replacing APIM or the cost on having a security breach.

...and they got the analysis wrong.

 

[VindictivePantz]

The requirement for administrator access and the disabling of anti-virus raises all sorts of security concerns if the laptop/device being used is ever connected to email, the internet, etc. Seems like an enticing backdoor.

Assuming Ford's security within the vehicle between modules, particularly the modem, are rock-solid so risk may be low - but if there's a weakness that would allow someone to get access to the modem, that's not good.

And yes, I have a well-fitting tin-foil hat , but given all of the security challenges Tesla, Kia, and Hyundai have had over the past few months, it's something to keep an eye on.

 

[MellowJohnny]

In most cases, the dealers inadvertently locked the APIM update process many months ago while doing BlueCruise updates (21G01). When the APIM update wasn't working, they just haphazardly ran Module Update Repair without realizing it requires the USB adapters, and unknowingly started the 20-day lockout countdown (they probably didn't read the TSB at all). The dealer likely never came back with the USB adapters in the 20-day window, and just returned the car to the customer without working BlueCruise after giving up. As a result, there may be hundreds or even thousands of 2021 Mach-E's with locked APIMs that will no longer receive APIM updates, which may impact the functionality of BlueCruise. Dealers will need to order and replace the APIM to fix this. Some people have been waiting 2-3 months for a replacement APIM in their quest to get working BlueCruise.

If you got Power-Up 3.5.3 or 22-PU0707-SCH-POPB installed recently you should be okay. The version numbers are below if you check on the SYNC screen:
Version: 22177_PRODUCT
Revision: 473
Version: 22228_PRODUCT
Revision: 539

If you have a SYNC version that starts with 21XXX, you should contact your dealer with this TSB as you probably have an issue receiving SYNC updates.

Holy crap. Really shows that the old "hit it with a hammer" mentality when working with software-driven vehicles is a recipe for disaster. Most mechanics are likely used to being able to actually "see" what's wrong - worn ball join, warped rotors, broken / leaking hose etc etc etc. With software you can't "see" what's broken, just that it doesn't "work".

I'm assuming EV techs have diagnostic tools - how would a tech know the APIM is bricked? It's a bit scary that people on this forum know more than most EV techs.

These are expensive mistakes.

 

[SnBGC]

Yeah, self-updaters are going to read the directions and have the USB adapters because they don’t want to do anything wrong. It’s been the dealers causing problems.

Greg, there are several 3.5.x updates and the A/C button doesn’t change until you get 3.5.3.

That is interesting. Last update I accepted is 3.5.2 and Alexa appeared and the A/C button was relocated. I never saw nor accepted a notice for 3.5.3. The next notice I received was for 3.5.3.3 which I just let expire and it hasn't returned.

@Kamuelaflyer and I suspect that 3.5.3 installed by itself. Does that sound possible? Perhaps 3.5.2 and 3.5.3 are part of a single update that split into two parts? So accepting the first might have also accepted the second. Makes sense because the release notes did say something about this one taking a little while longer. I didn't get the Alexa icon or A/C button relocation until much later in the day (if I remember correctly...)

 

[Kamuelaflyer]

That is interesting. Last update I accepted is 3.5.2 and Alexa appeared and the A/C button was relocated. I never saw nor accepted a notice for 3.5.3. The next notice I received was for 3.5.3.3 which I just let expire and it hasn't returned.

@Kamuelaflyer and I suspect that 3.5.3 installed by itself. Does that sound possible? Perhaps 3.5.2 and 3.5.3 are part of a single update that split into two parts? So accepting the first might have also accepted the second. Makes sense because the release notes did say something about this one taking a little while longer. I didn't get the Alexa icon or A/C button relocation until much later in the day (if I remember correctly...)

IIRC, I was told by a Ford person that 3.5.3.3 was supposed to install regardless of the automatic update setting. Ok. That explains one. But I know 3.5.3 installed itself as I got temporarily stranded at the grocery store.