23C38 – Update SYNC Software – 2022-2023 Ford F-150 Lightning

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November 28, 2023 NHTSA CAMPAIGN NUMBER: 23V801000

Deactivated Electronic Stability Control/FMVSS 126

Failure to reset the ESC to active may result in the driver unknowingly operating the vehicle without electronic stability control, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V801

Manufacturer Ford Motor Company

Components ELECTRONIC STABILITY CONTROL

Potential Number of Units Affected 5,118

 

Summary

Ford Motor Company (Ford) is recalling certain 2022-2023 F-150 Lightning vehicles. The SYNC software may fail to activate the electronic stability control (ESC) system at the beginning of each ignition cycle. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, “Electronic Stability Control Systems.”

 

Remedy

The Accessory Protocol Interface Module (APIM) software will be updated by a dealer or through an over-the-air (OTA) update, free of charge. Owner notification letters are expected to be mailed December 18, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23C38.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


November 30, 2023

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 23C38
Certain 2022 – 2023 Model Year F-150 Lightning Vehicles
Update SYNC Software

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F-150 Lightning 2022 Rouge EV Center October 14, 2021 through October 19, 2022
2023 August 15, 2022 through April 18, 2023

US population of affected vehicles: 5111. Affected vehicles are identified in OASIS and FSA VIN Lists.

Note: Some vehicles may be in the process of being repaired at the plant. Monitor OASIS before opening an RO and/or beginning a repair.

 

REASON FOR THIS COMPLIANCE RECALL

All of the affected vehicles may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No.126, Electronic Stability Control Systems, due to an error in a previous software update. On the vehicle, it may be possible that when you place the vehicle in certain drive modes with reduced Electronic Stability Control (ESC) restriction (ESC Off telltale illuminated) and the ignition is cycled, ESC will not return to the required default state (ESC Off telltale off). This results in noncompliance to FMVSS No. 126.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to update the Accessory Protocol Interface Module (APIM) software. This service must be performed on all affected vehicles at no charge to the vehicle owner. For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles.

To assist vehicle owners to have this repair completed, dealers should:

  • Arrange to pick up the owner’s vehicle and drive it to the dealership for repairs.
    • Re-deliver the owner’s vehicle after repairs have been completed.
  • Pick-Up & Delivery should be made available for all customers. Refer to the Rental and Claiming sections for further details.

 

OVER-THE-AIR (OTA) UPDATES (FORD POWER-UP):

  • In addition to you being able to update vehicles now using FDRS, Ford has deployed an OTA software update in mid-November 2023.
  • Before scheduling service for an OTA-capable vehicle, please verify through PTS that the FSA is still open (OASIS) and that the vehicle has not already received the OTA update.
    1. Verify FSA is still open by viewing the “Outstanding Field Service Actions” on the OASIS results page on PTS. (Note: If the OTA update was recently downloaded onto the vehicle the FSA may still show as open)
    2. If the FSA is still open in the Outstanding Field Service Actions section, proceed to the tab titled “Connected Vehicle”. In the “Over The Air Update 60 Day History”, you can determine if an OTA update occurred on the affected module by viewing the

“Completion Status”, which should show “Campaign Successful”. The “Release Notes” will also indicate that the campaign was successfully downloaded onto the vehicle. (Note: the FSA may still show as open in the Outstanding Field Service Actions section of PTS even though the OTA update was successfully downloaded onto the vehicle. This FSA will eventually be removed from the Outstanding Field Service Actions screen of PTS.)

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of December 18, 2023. Owners will be given the option of installing the software update themselves, or they can have their dealer perform the service for them.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $26,315 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

MOBILE SERVICE REPAIR ASSESSMENT LEVEL

  • All repairs in this program have the following assessment level:

– Not a Mobile Service Repair

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this compliance recall. Owners should contact their dealers for an appointment to have their vehicles remedied as soon as practicable.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting, or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

BRANDED / SALVAGED TITLE VEHICLES

Affected branded / salvaged title vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with a SYNC software update for this issue.

 

RENTAL VEHICLES

Rental vehicles are not approved for this program.

 

PICK-UP & DELIVERY- Participating Dealers

Dealers participating in the Remote Experience Program:

  • Ford Dealers – Refer to EFC12071, 2023 Remote Experience Program, Pick-Up & Delivery Offset section for additional details.

 

PICK-UP & DELIVERY- Non-participating Dealers

Ford Dealers not participating in the 2023 Remote Experience Program for Pick-Up & Delivery are authorized to claim unique services for completing this program.

  • Dealers are authorized to claim one-half labor hour per repair for vehicle Pick-Up & Delivery services. Refer to Labor Allowances for details.
  • Dealers must retain a Vehicle Pick-Up & Delivery Record with the repair order documentation.

 

PARTS REQUIREMENTS

Parts are not required to complete this repair.

 


CERTAIN 2022-2023 MODEL YEAR F-150 LIGHTNING — SYNC MODULE REPROGRAMMING

SERVICE PROCEDURE

Module Programming

NOTE: Program appropriate vehicle modules before performing diagnostics and clear all DTCs after programming. For DTCs generated after programming, follow normal diagnostic service procedures.

1. From the vehicle settings menu disable the 30 minute max idle option.

• From the center display press the vehicle settings button and turn off the 30 minute max idle setting. See Figure 1.

 

2. Install the Ford Diagnostic and Repair System (FDRS) Scan tool and required reprogramming or diagnostic components. Check the vehicle’s State Of Charge Parameter Identification Data (PID) by performing the following:

• Launch the Ford Diagnostic and Repair System (FDRS) and navigate to toolbox tab > datalogger

BCM and select BATT SOC PID.

• Ensure that the BATT_SOC PID reads over 80%. If the PID is less than 80%, fully recharge the vehicle’s 12-volt battery using the appropriate Rotunda battery tester and charger.

• Remove the charger from the vehicle and using FDRS, navigate to toolbox tab > BCM > Reset Battery.

• Monitor Sensor Learned Values application. Perform the BMS reset.

• Connect the Rotunda battery tester and charger and set it to maintain 12.6 to 13.6 volts. Monitor the voltage real time using the indicator at the bottom right corner of FDRS to ensure that it is within this range.

3. Connect a battery charger to the 12V battery.

• Use of a heavy-duty charger is recommended to maintain proper battery voltage during this procedure.

NOTE: Verify that the negative cable of the charger is installed on a chassis or engine ground and not the 12 volt battery negative terminal to prevent the battery saver mode from activating on the vehicle.

NOTE: If the diagnostic software does not load or if the vehicle cannot be identified properly, make sure there is a good internet connection and the VCM is properly connected to the DLC.

NOTE: VCM 3 is recommended for improved data download time.

4. Log into Ford Diagnostic and Repair System (FDRS). Ensure FDRS is updated to the latest version at 34.5.1 or higher.

NOTE: A 32GB or larger USB flash drive is required for Accessory Protocol Interface Module APIM software updates. 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 format the USB flash drive:

• Right click on the USB flash drive

• Select Format, select exFAT for the File System

• Select Default Allocation Size for the Allocation Unit Size.

• De-selecting Quick Format is not necessary and will result in a lengthier operation. See Figure 2.

 

5. Start a new FDRS session.

NOTE: Vehicle information is automatically retrieved by the diagnostic software and a Network Test is run. Vehicle identification data appears on the screen when this is complete.

6. Select Toolbox tab.

7. Select Software Updates tab to see updates available.

8. Are there any updates available for the APIM?

Yes – Proceed to Step 9.

No – This completes the Field Service Action.

9. When prompted by the FDRS, connect the USB flash drive to the personal computer (PC).

10. When prompted by the FDRS, safely remove/eject the USB flash drive from the PC, turn the vehicle to Key On Engine Running (KOER), and connect the USB to the media hub to install the software update. The update starts automatically and may take 10 minutes or longer to complete.

NOTE: It may take up to 5 minutes for the vehicle to recognize the USB flash drive with software update.

11. For APIM USB software updates when SYNC touchscreen prompts to restart the vehicle:

• Turn the vehicle OFF.

• Wait ten minutes.

• Turn the vehicle to KOER.

12. Leave the USB drive inserted into the vehicle, until the vehicles infotainment display screen states programming successful.

NOTE: It may take up to 5 minutes before SYNC touchscreen displays Update Successful pop up.
After 5 minutes if “Successful” pop up is not shown on SYNC touchscreen, remove the USB and select YES on the FDRS “Was the USB Update Successful” prompt (FDRS verifies if the module software update was successfully installed on the module).

13. From the list on the RH side of the screen, select Self-Test and click RUN.

14. Click the Run Selected Tests button in the lower right.

15. Click the Clear & Retest button at the top of the screen to clear DTCs in all modules.

16. On the Vehicle’s Center Display, go to the vehicle’s Settings Menu and Re-Enable the 30Min Max Idle option.

17. Remove and disconnect the FDRS Scan tool and required reprogramming or diagnostic components.
Disconnect the battery charger from the 12V battery once the programming has completed.

 

Important Information for Module Programming

NOTE: When programming a module, use the following basic checks to ensure programming completes without errors.

• Make sure the 12V battery is fully charged before carrying out the programming steps and connect FDRS/scan tool to a power source.

NOTE: A good internet connection is necessary to identify the vehicle and to load the diagnostic software.

• Inspect Vehicle Communication Module II (VCM IIeBay)/Vehicle Communication and Measurement Module (VCMM) and cables for any damage. Make sure scan tool connections are not interrupted during programming.

• A hardwired connection is strongly recommended.

• Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC system, etc.) and close doors.

• Turn the accessories back on after programing has completed.

• Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio,etc.).

• Follow all scan tool on-screen instructions carefully.

• Disable FDRS/scan tool sleep mode, screensaver, hibernation modes.

• Create all sessions key on engine off (KOEO). Starting the vehicle before creating a session will cause errors within the programming inhale process.

 

Recovering a module when programming has resulted in a blank module

a. Disconnect the VCMII or VCMM from the data link connector (DLC) and your PC.

b. After ten seconds, reconnect the VCMII/VCMM to the DLC and the PC. Launch FDRS. The VCMII/VCMM icon should turn green in the bottom right corner of the screen. If it does not, troubleshoot the FDRS to VCM connection.

c. If you are using the same FDRS as the initial programming attempt, select the appropriate VIN from the Vehicle Identification menu. If you are using a different FDRS, select “Read VIN from Vehicle” and proceed through the Network Test.

d. In the Toolbox menu, navigate to the failed module and Download/Run Programmable Module Installation (PMI). Follow the on-screen prompts. When asked if the original module is installed, select “No” and continue through the installation application.

e. Once programming has completed, a screen may list additional steps required to complete the programming process. Make sure all applicable steps are followed in order.

 


Ford Power-Up Software Updates

How to turn on Automatic Updates and Set a Recurring Schedule

Ford Power-Up software updates are downloaded and installed over-the-air using either an external Wi-Fi or
FordPass™ Connect (vehicle modem). Most software updates will happen seamlessly in the background, if
both of the following have been done on your vehicle:

1. Automatic Updates is turned ON.

2. A Recurring Schedule has been set.

We recommend scheduling updates for overnight or at a time that you will not need to enter or use the vehicle.

 

To set a recurring schedule:

1. Tap Settings on your vehicle’s SYNC screen.

2. Choose System (or Software) Updates.

3. Press Schedule Updates (or Recurring Update Schedule).

 

Depending on your vehicle you will either:

4. Choose Schedule.

5. Choose your preferred days and times.

6. Press Save.

or

4. Select one of the Preset options OR Select Custom Schedule.

5. If Custom Schedule, choose your preferred days (minimum of 2) and time.

6. Exit the screen (Schedule is auto saved).

 

To confirm Automatic Updates is turned ON:

1. Tap Settings on your vehicle’s SYNC screen.

2. Choose System (or Software) Updates.

3. Confirm Automatic Updates is toggled to ON.
Prior to software download and installation, you will receive a reminder in your vehicle (24 hours prior) and in
your FordPass® App. You can reschedule up to 2 mins before the update begins.

Important Notes:

Ford Power-Up software updates are not deployed to all vehicles at the same time.

• If you choose to turn Automatic Updates OFF, you will not receive this software update unless you have
previously consented to all prior updates.

• To confirm that this recall is included in the software update and is available or successfully installed in
your vehicle, tap Settings on your vehicle’s SYNC screen, select System (or Software) Updates and
select Update Details to view the latest release notes. You will also get an Update Successful alert in
the message center of your FordPass® app.

If you are unsure if you have received the software update for this recall or have any questions regarding
software updates, please call our specially trained Software Update Customer Relationship Center at:
1-833-389-0848.

 


Chronology :

October-November 2023
On November 9, 2023, an issue pertaining to the persistence of user-selected drive modes, including ESC status, between ignition cycles on certain 2022 and 2023 model year Ford Lightning vehicles was brought to Ford’s Critical Concern Review Group (CCRG) for review. The carry over of drive modes between ignition cycles was first identified during the weekend of October 27, 2023, when Ford personnel noticed that the last selected drive mode began to carry over between ignition cycles after receiving Over-the-Air (OTA) software update 6.3.0 (SYNC version 1.9.4). The OTA software deployments were halted on October 27, 2023 for an unrelated concern.

Certain drive modes, such as Off-Road Mode, change the performance of Electronic Stability Control (ESC) operation. The F-150 Lightning Off-Road mode has a less restrictive ESC function to allow for improved traction on loose surfaces such as soft soil. The CCRG investigation determined that the SYNC 1.9.4 update caused the reduced ESC function tied to Off-Road mode to carry over between drive cycles without user input instead of returning to default ESC operation with each drive cycle.

Federal Motor Vehicle Safety Standard (FMVSS) No.126 Electronic Stability Control Systems allows a driver to turn off the ESC operation in certain circumstances. However, Section 5.4.1 of FMVSS No, 126 explicitly requires that the vehicle’s ESC system return to the manufacturer’s original default ESC mode at the initiation of each ignition cycle. The CCRG reviewed the certain exclusions in Section 5.4.1 of FMVSS No. 126, but determined that they do not apply to these F-150 Lightnings.

CCRG reviewed the deployment records for the OTA and determined that 5,118 number of vehicles received the OTA update version 6.3.0.

On November 17, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action.

Ford is not aware of any reports of accident or injury related to this condition.

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
FORD F-150 LIGHTNING 2022-2023

 


3 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-23V801-2565.PDF 215.988KB

RCLRPT-23V801-2565

 


Recall Acknowledgement

RCAK-23V801-3529.pdf 645.417KB

RCAK-23V801-3529

 


Manufacturer Notices(to Dealers,etc)

RCMN-23V801-1048.pdf 635.98KB

RCMN-23V801-1048

 


Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V801&docType=RCL

 


 

Reprogramming

Service Information & Reprogramming

 

Module Reprogramming

Diagnostic Software Interface Device Complete Vehicle Diagnostics Module Programming
1996-2017
Model Year
2018-Present
Model Year
1996-2017
Model Year
2018-Present
Model Year
IDS/FDRS VCM, VCM IIeBay, VCMM X X X X
FJDS/FDRS Compatible J2534 Devices
(Including VCM IIeBay and VCMM)
  X X X

Detailed system requirements, installation, and support information for each product is located under the diagnostics tool support tab for each product.

 

Integrated Diagnostic Software (IDS) / Ford Diagnosis & Repair System (FDRS)

For use with VCM I, VCM IIeBay, VMM and VCMM hardware devices only. The complete factory Ford Motor Company vehicle diagnostic tool that provides complete dealership level vehicle diagnostic coverage for all 1996 to present Ford, Lincoln and Mercury vehicles. The IDS software includes time based access to the IDS software, software updates and calibration files.

 

Ford J2534 Diagnostic Software (FJDS) / Ford Diagnosis & Repair System (FDRS)

For use with compatible J2534 hardware devices. FJDS software provides Ford Module Programming functionality that covers 1996 to present Ford, Lincoln and Mercury module reprogramming functions, plus complete dealership level vehicle diagnostic software for all 2018 to present Ford and Lincoln vehicles. The FJDS software license includes time based access to the FJDS software, software updates and calibration files.

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light CarDAQ-Plus
23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light CarDAQ-M
23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light VSI J2534 ECU Reprogrammer
23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

Mongoose-Plus J2534

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

RAP2 OEM J2534 Remote Reprogramming Tool

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909

23C38 - Update SYNC Software - 2022-2023 Ford F-150 Lightning | small light

GODIAG J2534

 


Latest Calibration Information

Module Build Data (As-Built)

Use VIN to obtain As-Built data

www.motorcraftservice.com

 


 

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  • 【Wireless with advanced networking functions】Built-In Wireless with advanced networking functions and data storage. Fast performance ensures reprogramming even the newest controllers & Internet upgradable and updatable. Autel MaxiFlash Elite is compatiable with MaxiSYS MS908S, MaxiSYS MS908S Pro , MaxiSYS MS908CV, MaxiCOM MK908, MaxiCOM MK908 Pro, MaxiSYS Elite, MaxiSYS Elite II and Personal Computer
  • 【SAE J2534-1 & J2534-2 Standards】Autel MaxiFlash Elite J2534 is a fully compliant SAE J2534-1 & SAE J2534-2 (March 2006) device, which performs standard PassThru J2534 functionality: Compatible with for Toyota Techstream, Volvo VIDA, Honda HDS, Jaguar-Land Rover IDS and BMW 3G for OEM diagnostics. Autel MaxiFlash J2534 is also specially designed to provide users with P-C communication and ECU reprogramming capabilities on any modern vehicle diagnostic bus, reliability and flexibility.
  • 【Supports simultaneous communication Definition in J2534-1】Autel MaxiFlash Elite Reprogramming Device J2534 supports simultaneous communication definition in J2534-1, running 3 protocols at the same time, which greatly improves reprogramming and diagnostic speed. Embedded with the ARM9 Dual-core processor (clocked up to 500MHz), which further boosts the communicating speed.Rugged aluminum case with non-slip rubber end caps, capable of withstanding harsh environment.
SaleBestseller No. 5
Latest Version ECUs Programmer SM2Pro J2534VCI Read Write 67IN1 Dongle Suiatble for Efficient ECUs Programming Durable Diagnostic Tool Plastic ECUs Programmer Vehicle Repair Tool Engine Diagnostic
  • Stay up-to-date with thelatest firmware and support of the SM2Pro J2534VCI ECUs programmer, ensuring reliable perform and optimalresults.
  • The SM2Pro J2534VCI ECUs programmer is a trustedtool for professional technicians, offering comprehensive functionality and easy integration into your workflows.
  • The SM2Pro J2534VCI ECUs programmer offersadvanced functionality for efficient and precise ECUs programming.
  • With its 67IN1 dongle & OBDcompatibility, the SM2Pro J2534VCI ECUs programmer provides a versatilesolution for read and write operations.
  • Experienceseamless ECUs programming with the SM2Pro J2534VCI, designed to streamlines the read and write processes for enhanced efficiency.

Last update on 2024-02-16 / Affiliate links / Images from Amazon Product Advertising API

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