I have version 5.9 of the SYNC software on my car and I have downloaded the update from the ford website based on my VIN.

I have followed the instructions as per their website - downloaded to my computer, extracted and then copied to my USB stick (which is FAT32 as requested).

When I plug into my car it starts the update process, says SYNC is rebooting and about 2 minutes later I get a message saying 'Installation Failed' then 'SYNC is rebooting' again and then nothing.

Does anyone have suggestions on how I can get this to work?

I've looked on other forums, but they all seem a few years old so some of the issues they had appear to have been corrected (the code unzipping as 1 big line, hidden letters after the code....). The only discrepancy I can see is in the autoinstall file, the 1 line says KB and the other KC, I've tried amending this so they match but that didnt make a difference.

I also get a corruption error when unzipping the SyncMyRide folder, but that file doesnt appear in the install or autoinstall folders so not sure if it is actually required.

Any help would be greatly appreciated as it's getting really frustrating now and cant afford to take it to a garage for them to just plug it in 🙁.

Try formatting the stick to exfat instead.

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I tried it with exfat and the other one beginning with an N but my car doesnt recognise that there is anything on the stick.

Just bumping this thread. I have a 2016 Ford Fiesta (1.0 Ecoboost 100). It has SYNC 1.1, version 5.8. Like @Vasten, I get an 'installation failed' message when trying to install from my FAT32-formatted USB with the original Ford update files downloaded from the Ford website. I tried twice and got the same message. The third time, I stopped the process after 40 minutes; nothing was happening. The system still works fine, so it didn't mess up the current software. As @Vasten says, all the issues from 2018-19 about files not being found do not seem to be the problem in my case.

My hunch is that the installation isn't actually starting - or stops immediately - and then eventually times out. It's the time-out that triggers the 'installation failed' message (which is both on the screen and audible). 

Does anyone have any hints? Or, almost as good, can someone with a similar generation of SYNC who has performed the update actually explain what happens when it is in process and then successful? When I look at the instructions on the Ford website (here), I notice that I get as far as 'Installing SYNC file' in step 14, but no further. I've never heard a voice prompt saying "Installation is in progress".

Thanks!

My problem also seems similar to this person's problem back in 2018. The person never wrote back or posted again, so I have no sense of whether the issue was resolved.

 

I finally fixed my problem by using a different USB stick (I had tried 2 already, a 2 GB USB 2.0 and a 32 GB USB 3.0). In the end, I put the update files on a 4GB USB 2.0 stick and it worked. It took almost exactly 20 minutes to update to 5.11, as per the official instructions.

Hope this helps anyone else who is struggling with this!