Ford Sync3 v3.0 “The installation has run out of space” Upgrade Failure or IT Guy Buys a Truck.

This is not strictly IT but then again it is so I am posting it here. I recently purchased a 2016 Ford and found I needed to update the Sync3 software to use “CarPlay” with my phone. It sounds easy but turned out not to be.

Ford provides install instructions and the ‘tar’ files for the upgrade via a download on their web site. You need to create an account and register your vehicle to get the software. Then their instructions are basically to:

  1. Put the extracted files on a exFAT formatted USB
  2. Start your vehicle and with the vehicle running plug the USB

The install should start automatically. When it is complete you remove the USB, shut the vehicle off, wait 5 minutes and restart it. Simple process but my upgrade failed with the error:

Installation Failed

The installation has run out of space or does not work with this version.

Close

Also, when it restarted, the version still showed as 1.0 and the “Gracenote” version was now blank.

I tried it multiple times with multiple USB drives and could not get around the error. Sometimes the install would not generate the error but just hang with the “Updating” message on the screen and never end. Sometimes I got the error after giving up and restarting the vehicle. The install should take 30 minutes max but I waited as long as 2 hours before I gave up. After burning a quarter tank of gas, I called Ford Support but they had no clue.

Looking on the Internet I did see references to running the install in two stages. This was for v2.2, not v3.0 but I decided to try it anyway. In the installation download is an ‘.lst’ file with the install instructions and a folder “SyncMyRide” with seven ‘tar’ files. The ‘lst’ file for my v3.0 upgrade was:

; SYNC3 Consumer Assembly Upgrade - Release 3.0.21 - Only for My16 NonNav/NonEU assemblies.

[SYNCGen3.0_3.0.19205_PRODUCT]
Item1 = HB5T-14G386-THA
Open1 = SyncMyRide\HB5T-14G386-THA.tar.gz
Item2 = HB5T-14G386-TBB
Open2 = SyncMyRide\HB5T-14G386-TBB.tar.gz
Item3 = GB5T-14G386-SC
Open3 = SyncMyRide\GB5T-14G386-SC.tar.gz
Item4 = JR3T-14G391-BF
Open4 = SyncMyRide\JR3T-14G391-BF.tar.gz
Options = AutoInstall

[SYNCGen3.0_ALL]
Item1 = JR3T-14G381-AS
Open1 = SyncMyRide\JR3T-14G381-AS.tar.gz
Item2 = JR3T-14G423-BB
Open2 = SyncMyRide\JR3T-14G423-BB.tar.gz
Item3 = GB5T-14G386-AB
Open3 = SyncMyRide\GB5T-14G386-AB.tar.gz
Options = Delay,Include,Transaction

As you can see it is already divided into two separate installs — [SYNCGen3.0_3.0.19205_PRODUCT] and [SYNCGen3.0_ALL]. When I rem’d out the second install the first ran correctly, prompted me to remove the USB and restart the vehicle. When it restarted, the version still showed as 1.0 and the ‘Gracenote” version was still blank. But I was not getting an error. Here is the first half ‘lst’ file:

; SYNC3 Consumer Assembly Upgrade - Release 3.0.21 - Only for My16 NonNav/NonEU assemblies.

[SYNCGen3.0_3.0.19205_PRODUCT]
Item1 = HB5T-14G386-THA
Open1 = SyncMyRide\HB5T-14G386-THA.tar.gz
Item2 = HB5T-14G386-TBB
Open2 = SyncMyRide\HB5T-14G386-TBB.tar.gz
Item3 = GB5T-14G386-SC
Open3 = SyncMyRide\GB5T-14G386-SC.tar.gz
Item4 = JR3T-14G391-BF
Open4 = SyncMyRide\JR3T-14G391-BF.tar.gz
Options = AutoInstall

;[SYNCGen3.0_ALL]
;Item1 = JR3T-14G381-AS
;Open1 = SyncMyRide\JR3T-14G381-AS.tar.gz
;Item2 = JR3T-14G423-BB
;Open2 = SyncMyRide\JR3T-14G423-BB.tar.gz
;Item3 = GB5T-14G386-AB
;Open3 = SyncMyRide\GB5T-14G386-AB.tar.gz
;Options = Delay,Include,Transaction

I then ran the second half by reversing the rem’d out lines. This failed with the same error as the entire install. The error was in the second half! So I changed the file to divide the second half install into 3 separate parts.

; SYNC3 Consumer Assembly Upgrade - Release 3.0.21 - Only for My16 NonNav/NonEU assemblies.

;[SYNCGen3.0_3.0.19205_PRODUCT]
;Item1 = HB5T-14G386-THA
;Open1 = SyncMyRide\HB5T-14G386-THA.tar.gz
;Item2 = HB5T-14G386-TBB
;Open2 = SyncMyRide\HB5T-14G386-TBB.tar.gz
;Item3 = GB5T-14G386-SC
;Open3 = SyncMyRide\GB5T-14G386-SC.tar.gz
;Item4 = JR3T-14G391-BF
;Open4 = SyncMyRide\JR3T-14G391-BF.tar.gz
;Options = AutoInstall

;[SYNCGen3.0_ALL]
;Item1 = JR3T-14G381-AS
;Open1 = SyncMyRide\JR3T-14G381-AS.tar.gz
;Options = AutoInstall

;[SYNCGen3.0_ALL]
;Item1 = JR3T-14G423-BB
;Open1 = SyncMyRide\JR3T-14G423-BB.tar.gz
;Options = AutoInstall

;[SYNCGen3.0_ALL]
;Item1 = GB5T-14G386-AB
;Open1 = SyncMyRide\GB5T-14G386-AB.tar.gz
;Options = Delay,Include,Transaction

Note: I had to add a header to each part, an ‘options = AutoInstall’ line to the first two, and change the ‘Item’ and ‘Open’ lines for each to ‘1’ to reflect the first, and only, item in each.

I then un-rem’d each part to do the JR3T-14G381-AS and JR3T-14G423-BB installs one at a time. My goal was to determine which part was failing. But that is not what happened.

The AS install worked and prompted me to restart the vehicle. I waited 5 minutes (this may be folklore but I did it anyway) and when I restarted it showed version 3.0! But, the “Gracenote” version was still blank. A partial victory. After the BB install it did not request a restart but I did it anyway. The “Gracenote” version now showed as 1.1.1.1130 (GL-0011.) At this point I had an upgraded system.

Victory!

I then ran the GB5T-14G386-AB install and it generated the ‘.xml’ file in the “SyncMyRide” folder that you upload to Ford to verify the installation. I uploaded the file and Ford accepted it.

Why did I need to do this? I am not sure. It was apparently running out of space trying to do the AS and BB installations at one time. An artifact left behind by a previous install? Restricted space due to compromised hardware? Differences in actual physical memory size from different suppliers of the APIM module? The only other thing I can think of is that because I also have Sirius Radio and that used a little space in the Sync3 system. A non-Sirius, non-Nav system would work? Maybe, but I have no way to test the theory.

Whatever it was, if you have this issue on a 2016-1018 Ford Sync3 system upgrade, this approach may work for you. More detailed information on this can be found in another of my posts ”Fixing Sync3 Upgrade ‘Out Of Space’ Errors”.

If you are doing this on a MAC, you may also want to read the comment by ‘Themi Mintzas’ about extracting the download and file name changes on the ”Fixing Sync3 Upgrade ‘Out Of Space’ Errors” post referenced above.

-Nick

41 thoughts on “Ford Sync3 v3.0 “The installation has run out of space” Upgrade Failure or IT Guy Buys a Truck.”

  1. I hope this works for me as I am having the exact same issue. One question from a non-tech gal; what do you mean by and how do you “rem” lines? I have modified my file to be exactly what yours shows (the three separate sections), but I do not know how to “rem” line.

    I am guessing rem is removed and that there is probably a simple way to “hide” them in programming, but not sure.

    Thanks in advance!!!

  2. Sorry Cynthia. Most people that would read this blog are Techies. I should not assume that since this is only a semi-technical subject.

    You are close. “rem” is techie for ‘Remark’. In this case, any line that starts with a ‘;’ (semicolon) is considered a ‘remark’ and ignored. The file in this post with the second part divided into 3 installs is all ‘rem’s so it will do nothing run as-is. To get each section to process, you remove the semicolons from the lines for that section. In this case, a section starts with a ‘[name]’ entry and ends with an ‘Options’ entry. To do the next section you put them back in the section you just did and remove them from the next one.

    I put a more detailed (for non-techies) post on Reddit on this. I added that link to the bottom of this post.

  3. THANK YOU!!!
    Im off to the garage after some modifications to the original “copy” 🙂

    Merry Christmas to you and yours!

  4. YOU, Sir, are the greatest!!!

    30 minutes later and my issue is resolved! As a non-techie, I cannot thank you enough for taking time to explain this and help me after multiple people at Ford could not.

    You are amazing!

  5. Worked as described. I see no indication of waze so that is probably only for the Nav version.
    I use waze on the phone with a magnetic vent mount anyhow.
    Any idea what we have gained by jumping through all these hoops?

  6. In my case got the upgrade to work and enabled CarPlay! You should now have the ability to use CarPlay although on an older vehicle you may also need to upgrade the hub too. If you plug in your iPhone and nothing happens with Sync3 version 3 installed, you probably need to replace the hub next. That part for my 2016 F-150 was ‘HC3Z-19A387-E Blue’ but it depends on the vehicle.

    I don’t use Waze but Waze should work from your iPhone via CarPlay once that works. I don’t think Nav makes a difference but I am no expert here since I don’t have it. There is yet another requirement and that is iOS 12 to add the app to CarPlay: same for Google Maps.

    Just more fun.

  7. THANK YOU SIR!!!!! I have been struggling to get this update to work on my 2016 mustang non-nav SYNC 3 v1.0 system and this was the only solution that worked!! I even took for dealership, wasted two days dealing with them and they wanted $1,100 to replace my APIM module, the module worked perfectly fine it just would not accept the update correctly, which made me believe that the file from Ford was messed up, but i could not figure out how. Thank you SO MUCH for posting this, saved me so much money and headache, all just to get Apple CarPlay haha!

  8. do you know if this works for cars with Nav? Looking at my file, it is not broken into 2 installs, just one big install of the 7 files”:

    ; SYNC3 Consumer Assembly Upgrade – Release 3.0.21 – Only for Nav/NA assemblies.

    [SYNCGen3.0_3.0.19205_PRODUCT]
    Item1 = HB5T-14G386-THA
    Open1 = SyncMyRide\HB5T-14G386-THA.tar.gz
    Item2 = HB5T-14G386-TCB
    Open2 = SyncMyRide\HB5T-14G386-TCB.tar.gz
    Item3 = JR3T-14G391-CE
    Open3 = SyncMyRide\JR3T-14G391-CE.tar.gz
    Item4 = JR3T-14G381-AS
    Open4 = SyncMyRide\JR3T-14G381-AS.tar.gz
    Item5 = JR3T-14G423-CB
    Open5 = SyncMyRide\JR3T-14G423-CB.tar.gz
    Item6 = HB5T-14G387-AAB
    Open6 = SyncMyRide\HB5T-14G387-AAB.tar.gz
    Item7 = GB5T-14G386-AB
    Open7 = SyncMyRide\GB5T-14G386-AB.tar.gz
    Options = AutoInstall,Delay

  9. No I do not because I have no NAV vehicles to test it on and have no feedback from anyone with NAV. Is this failing with an out of space error? If it is, I don’t see why this can’t be broken up the same way the as NON-NAV install.

    The NAV systems probably have more space to work with so you may not even have a problem. Perhaps why the downloaded install is not broken up at all?

    This link has the generic information to break it up: https://blog.pennic.com/fixing-sync3-upgrade-space-errors/

  10. NICK! YOU ARE A GENIUS AND THANK YOU SO MUCH FOR PUTTING IN THE TIME AND EFFORT TO HELP US IN THIS DILEMMA. IT WORKED!! I WOULD LOVE TO BUY YOU A BEER AND SHAKE YOUR HANDS IF IT WASN’T FOR THIS COVID19

  11. do you run these separate on different thumb drives or put them both on the same thumb drive. I’m not a computer guy at all but just trying to get my 2016 truck sync 3 updated from version 1

  12. Hi Nick,
    Extremely helpful, as I’ve almost gotten it installed on my truck (we’re using the same build, incidentally).

    Just wanted to confirm what Options you had selected for the final section of the 2nd half (the -AB file). I’m adding the AutoInstall, and I figure I should leave the other options in place? Or did you remove the “Delay”?

    Thanks again for a terrific explanation. As bad as I am at coding, even I was able to get the first 5 files installed…

  13. Thank you thank you. After multiple attempts to talk to ford they couldn’t help . You were spot ok and worked great.

    Thank you

  14. Nick!

    I been trying to figure this out for the past week and finally came across your post!

    I now have an updated Sync3 Version3 system thanks to your help.

    Appreciate you for the post!

  15. Hi Nick, I’m having the same issue with my 2016 F150. I don’t know anything about coding but I think I can follow these instructions. Thank you for figuring this out. I do have 2 questions?

    1. The first part of the file “ ; SYNC3 Consumer Assembly Upgrade – Release 3.0.21 – Only for My16 NonNav/NonEU assemblies.” Does this the remain for the very first install?

    2. Does it matter if it’s a usb 2.0 or 3.0?

  16. Only change the lines I referenced. The line you mention here is the first line and it begins with a “;” on the file as it comes from Ford. So, it is a comment and never does anything anyway. It is just there for documentation.

    USB 2.0 is just fine. The speed of the controller in the vehicle is what matters and I think they are still all 2.0. Vehicles are slow to catch up. At least it’s not an eight track! A 3.0 thumb drive should work into either 2.0 or 3.0. So, either one should work.

    Nick

  17. After trying ideas for almost a year, this one worked. Thank you Nick. You’re my 2020 IT hero!

    Summary: Use Notebook to modify the autoinstall.lst – Install only Section 1 (PRODUCT – smaller files) then split Section 2 (ALL – larger files) in 3 parts and install them separately.

  18. Followed all steps above and the install worked great. Swapped USB hub to the HC3Z-19A387-E, bought from the Ford dealer. Plugged my new iPhone 12 in with the Apple lightning cable and it just says device detected. Left new hub in and did the install all over again. Installed fine, but same result when I plug in my phone. Apple CarPlay does not come up and Sync does not display on the phone either (Settings, general, CarPlay). Does this take a few power cycles to fully complete everything?
    2016 F-150
    (Side note, phone and cable combo do work in a different vehicle with UConnect).

  19. It should work right away. You are sure it upgraded — the version is correct? Is the USB hub connector on fully? If that all checks out, it sounds like a question for Ford. Hub part is bad?

    Nick

  20. Went out and looked again. Turned the key on and it says “This USB device is not supported. Please remove”. Hadn’t seen this before. Actual hub PN is HC3T-14F104-BD which looks to the the new version of what my package was labeled as. This is the new hub with only the lightning cable plugged in, nothing else connected (not even my phone).
    Sync 3, V 3.0, build 20204.
    Gracenote 1.1.1.1130 (GL-0011).
    XML file created earlier from the install, uploaded to Ford and says everything was successful.
    No Apps show with nothing connected. When I plug my phone in, it says Device Connected and then shows an App, Pandora. I can choose a audio input source as my iPhone.
    I am lost. Maybe it will randomly start recognizing it.

  21. I can only help with the uprade which it looks is compete. Something is not right or broken: cord, phone or the hub. That is not the correct part number? You got an old hub in a new part box? My bet would be the hub is broken.

  22. Definitely not the cord or phone, works fine in another vehicle. Only thing I can find online is that HC3T-14F104-B replaced HC3Z-19A387-E.
    The bag was labeled as the A387, but actual part says F104. Unopened and straight from Ford. Probably worth a call to them Monday if it doesn’t magically update itself by then!

  23. Its not going to fix itself. If it says it doesn’t recognize the phone, its the wrong part, or it is broken. When I look for that part number I only see references to version 2.2 not 3. I think the parts guy grabbed the wrong box. Ford is your only solution (especially if you want your $ back). Or, just get one from eBay. 🙂

  24. Yeah I’m not sure what happened with the P/N. Looking on Ebay and there are a lot that say HC3Z-19A387-E but the photos show the HC3T-14F104-BD. Found a youtube video of a guy swapping, and he took the F104 out and put in the A387-B. Looks like I need to send this hub back and re-do.
    https://www.youtube.com/watch?v=E02uhxR9O5I
    Thanks for all the help.

  25. Nick, thank you for your instructions. I tried upgrading several months ago, but had no luck. This weekend I tried again with the same results. Searching for some help I came across your instructions. When I followed your instructions everything worked perfectly. Thank you for sharing your knowledge!

  26. Great job with the post. I was able to successfully update from 1.0 to 3.0 on my 2016 expedition non-nav.

    Thank you very much!

  27. Does this work for the latest version released in late 2020? I have a 2016 non nav with 1.0 and everytime I try to install, the error code “one or more bad installation files” will this fix this? Thank you

  28. I don’t know. Make sure the version is compatible with your vehicle and give it a try. ‘Bad installation files’ normally means the file is: missing – wrong name – in the wrong place. See the Mac comments if you are using a Mac.

    This post is about upgrading from the initial version to Build 19205 (Release 3.0.21 in the lst file banner). I just upgraded from Build 19205 to Build 20204 (Release 3.0.25 in the lst file banner). It did take twice to get it to take but I did not have to change the ‘lst’ file to get it to work. looks like Ford may be getting better. This, however, does not mean this will be everyone’s experience.

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