Reprogramming used '14 Focus TCM for '12 Fiesta

[PancakeFord]

My car is 2012 Ford Fiesta built ~05/2012. The TCM module in it is acting up and I suspect needs to be replaced. I purchased a used TCM.
The casing of TCM that is currently in the car is stamped with '13 and it has paint markers writing on it. That tells me that it is not original to the car.
Hardware number for TCM currently in the car is AE8P-14F085-AC with the Calibration FA6P-7Z369-KC. SBL is AE8P-7J244-AB. Strategy is FA6P-7J104-KC.

Using 2.4.7 beta with OBDlink EX cable I was able to upgrade TCM that is currently in the car to following (available option was used):
Calibration level: FA6P-7Z369-KD
SBL: (stayed the same)
Strategy: FA6P-7J104-KD

There was not enough time testing to see if firmware update resolved TCM issue, but I suspect it did not.

Used TCM from '14 Focus has a different Hardware number AE8P-14F085-AE.
Calibration level: G1FP-7Z369-AC
SBL: AE8P-7J244-AB (same as "original" TCM)
Strategy: G1FP-7J104-AC

Available to program shows the same calibration and other numbers, so I have tried to hit program to make sure it will program same thing over (should I not have done that?). Followed instructions, dashboard went dark, hazards flashing for 2-3 seconds, and then errors in the log.

(OK) [13:39:20.271] TCM Module firmware update has been started
(WARN) [13:39:20.281] Reading vehicle info...
(WARN) [13:39:34.848] Total size: 1.50 Mb. Estimated duration: 2m - 4m
(WARN) [13:39:46.387] Loading SBL to primary module...
(ERR) [13:39:48.906] Unable to enter programming session, incorrect initial vehicle conditions
(ERR) [13:39:49.217] Service procedure has been interrupted

Car battery is new and connected to maintainer/charger. In short, all conditions are exactly the same when I updated "original" TCM.

With this used TCM, there are few DTC from PCM and IPC stating something along the lines of TCM not communicating or responding. Could this be the reason why it cannot be programmed? This is probably a question outside of FORScan support's scope, but at the moment idk who else would know.

After this failed, I tried custom option and selected Calibration level file whose middle part number matched with old and the prefix was from the "original" TCM after update. Process errored out with the same outcome, so I suppose there was no harm done anyway.

Am I over my head trying to update this used module for my fiesta, or can it be done? Appreciate the help.

[PancakeFord]

Some screenshots as well.

"Original" refers to TCM that is currently in the car and is working, albeit with issues. In no way is it the original TCM that came with the car from the factory. It was replaced prior to my ownership of the car.

"Original" TCM before updating firmware (I clicked on download after taking screenshot for boxes to show green)

original module before update.PNG (35.33 KiB) Viewed 10405 times

"Original" TCM after updating firmware

original module after update.PNG (34.91 KiB) Viewed 10405 times

Used '14 Focus TCM prior to attempting firmware update

new module before update.PNG (33.6 KiB) Viewed 10405 times

Connection settings page

connection settings.PNG (52.61 KiB) Viewed 10405 times

DCTs with used '14 Focus TCM

dtcs with new module.txt

(1.85 KiB) Downloaded 489 times

Error when doing SBL test

error test run sbl.txt

(599 Bytes) Downloaded 449 times

Screenshot of error when programming used '14 Focus TCM

error with used tcm.PNG (35.11 KiB) Viewed 10405 times

[fatcam328]

I'm no expert but I would imagine your new TCM is likely not compatible. Sorry that I can't provide further advice. What makes you think the original TCM is faulty?

-Edit: Can you force program the Fiesta Calibration to the new TCM?

Tips: ensure your OBDLink EX cable is updated and your COM Port Latency Timer is 1ms

[FORScan]

This is a known issue with used TCM: be programmed as Fiesta, it cannot be installed to Focus, and vice versa. New clean module can be programmed to any model.

Exact reason is unknown, we suspect it is because of different networks and wiring in Fiesta and Focus (that are different platforms in fact). There should be 2 ways to program it:

1. In recovery mode with power off/on, to "catch" the programming session before the main strategy is loaded.
2. Program the TCM on the table.

[PancakeFord]

I'm no expert but I would imagine your new TCM is likely not compatible. Sorry that I can't provide further advice. What makes you think the original TCM is faulty?

-Edit: Can you force program the Fiesta Calibration to the new TCM?

Tips: ensure your OBDLink EX cable is updated and your COM Port Latency Timer is 1ms

That is what I am afraid might be the case, but also there are fiesta with new TCMs that have hardware number and with AE. Ford/dealer part numbers themself appear to be different between models. Transmission was serviced recently with a full clutch, forks, and seals replacement. From time-to-time clutch actuated by motor A will report as stuck. Swapping actuators does not move the issue to clutch B. Every time this issue happens, resetting TCM by power cycling it or the battery will make it shuffle gears and it will work great from there. Adaptations done on "original" TCM as well.

This is a known issue with used TCM: be programmed as Fiesta, it cannot be installed to Focus, and vice versa. New clean module can be programmed to any model.

Exact reason is unknown, we suspect it is because of different networks and wiring in Fiesta and Focus (that are different platforms in fact). There should be 2 ways to program it:

1. In recovery mode with power off/on, to "catch" the programming session before the main strategy is loaded.
2. Program the TCM on the table.

Ahh, that makes sense, that is probably where my misunderstanding that newer unprogrammed TCMs can be programmed to focus or fiesta, because they are blank. I misunderstood it and thought that used modules could be re-programmed for a different model.

I will try recovery mode in the car first, and then directly to TCM if that fails.

Besides things noted in post below, are there any other recommendations or notes to keep in mind during recovery?
https://forscan.org/forum/viewtopic.php?p=70631#p70631

Thank you for your input and prompt response

[PancakeFord]

Great news!

I tried to update firmware to factory in recovery mode and it worked. After that car recognized the TCM, I was able to shift out of park, all DTCs are gone, and transmission engaged into gears. I then updated firmware to latest available in normal (non recovery mode) without any issues. After that clearing DTC, warming up the engine, and going through clutch adaptations. Everything went great and engagements from neutral into reverse or drive are so much smoother versus original module.

I am waiting for something to clear up and will do a test drive and report back in few days if TCM replacement resolved my car's issue and if there are any other problems from this TCM being replaced.

How I got TCM in recovery?

1. What did not work. Disconnecting and reconnecting negative battery terminal within those 20 seconds (or until percentage goes up to 30% and times out). I tried multiple times. Tried powering on before pressing OK, after pressing okay. Did not work. I was about to remove TCM and try to do it on a bench.

2. What did work. Disconnecting battery's negative terminal, and during the 20 second period (or before % gets to 30% point) connecting and disconnecting negative until I noticed feedback in the log. Ignition was turned on during this process.

I remembered doing this with BMW ECU and figured I could give it a shot. This is probably not great or ideal for the car and TCM since, maybe. Those that want to repeat this, do it at your own risk. It worked for me.

I will post logs shortly if needed

[FORScan]

Thank you for the feedback, it is important information. However, I'm afraid I haven't understood the principial difference between the way 1(that didn't work) and the way 2 (that worked). In both cases you powered off/on the TCM by disconnecting and reconnecting the battery negative terminal. What is the principal difference between these ways? I'm asking because we'd like to improve the recovery mode.

[PancakeFord]

Thank you for the feedback, it is important information. However, I'afraid I haven't understood the principal difference between the way 1(that didn't work) and the way 2 (that worked). In both cases you powered off/on the TCM by disconnecting and reconnecting the battery negative terminal. What is the principal difference between these ways? I'm asking because we'd like to improve the recovery mode.

In first method I disconnected battery negative terminal when FORScan prompted ignition off. Then when prompted to power on module (in recovery), I connected the negative terminal of the battery once.

In second method, I connected and disconnected negative terminal 2-3 times within 1-2 seconds until noticed that log showed something SBL upload (or something along those lines). During these connects disconnects transmission attempted to do the shifting back and forth as it usually does when battery is reconnected.

Maybe the second method was just a coincidence, but I did try first method at least 15 times with no luck. The second method worked during first attempt. From BMW ECU programming I remember that doing this puts ECU into forced bootloader/recovery mode when it expects only a firmware and nothing else.

[FORScan]

Thank you very much for the information, will add it to our knowledge DB and programming guide.

[FORScan]

We have improved the Recovery Mode in v2.4, it should work much better now in this type of cases.