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? 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”.

Nick

15 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

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