So since I last reported, I've been in touch with Ford Sync support both via chat and over the phone. I re-downloaded the set of files for my 2015 C-Max Energi (Zip archive named EA5T-14D544-BA, if that matters) and installed them on a confirmed USB 2drive formatted as ExFAT. This was done on a Mac and there are some greyed-out system folders visible that on the USB drive (.Trashes, .Spotlight-V100, .fseventsd) that do not erase.
The guy I spoke to on Sync's phone support, who didn't seem too knowledgeable, simply found the official solution to my error message of "! Bad Installation File" and gave me the following instructions before sending me on my way:
Perform a Master reset
Make sure after the reset that the Welcome animation appears
Turn the vehicle off completely; Open the door; Get out of the car; Shut the door; Lock the car; Stay away for 5 minutes
After 5 minutes, unlock and re-enter the car and start it. Confirm that the Welcome animation appears, wait for home screen to show.
Insert the USB drive to start the installatio
Of course I did all this and still got the same error message.
RE: FILE STRUCTURE
There are conflicting instructions from Ford on what the file structure of the installation files should be. I'll call these A and B.
Instruction A says the unzipped archive should contain three items:
1. a folder named SyncMyRide in which several ".cab" and possibly other files reside
2. a file named "Autoinstall.lst"
3. a file named "DONTINDX.MSA"
Instruction B does not refer to the SyncMy Ride folder but simply instruct one to place all the files in the root directory of the USB drive.
The zipped archive I donwloaded did NOT include a SyncMyRide folder but instead had all the files loose. Most of these files had names that included "SyncMyRide\" in their names leading me to believe the files and Autoinsyall file have been updated to bypass the need for a folder of that name containing all the various installation files.
In fact, here is the contents of the Autoinstall.lst file:
; Application Directive Install for Gen 2 V3.10 (16180)
[SYNCGen2_4.23.11038]
[SYNCGen2_4.23.11063]
[SYNCGen2_4.23.11081]
[SYNCGen2_4.23.11134]
[SYNCGen2_4.26.12023]
[SYNCGen2_4.28.12156]
[SYNCGen2_4.29.12285]
Item1 = BT4T-14D546-EE
Open1 = SyncMyRide\BT4T-14D546-EE.cab
Item2 = EA5T-14D546-AKB
Open2 = SyncMyRide\EA5T-14D546-AKB.cab
Item3 = EA5T-14D546-HB
Open3 = SyncMyRide\EA5T-14D546-HB.cab
Item4 = EA5T-14D546-ACB
Open4 = SyncMyRide\EA5T-14D546-ACB.zip
Item5 = BT4T-14D546-FB
Open5 = SyncMyRide\BT4T-14D546-FB.cab
Item6 = EA5T-14D546-AHB
Open6 = SyncMyRide\EA5T-14D546-AHB.cab
Item7 = EA5T-14D546-ADB
Open7 = SyncMyRide\EA5T-14D546-ADB.cab
Item8 = EA5T-14D546-AEB
Open8 = SyncMyRide\EA5T-14D546-AEB.cab
Options = AutoInstall
[SYNCGen2_3.10.16180]
Item1 = EA5T-14D546-AFB
Open1 = SyncMyRide\EA5T-14D546-AFB.cab
Item2 = EA5T-14D546-BE
Open2 = SyncMyRide\EA5T-14D546-BE.zip
Item3 = EA5T-14D546-DF
Open3 = SyncMyRide\EA5T-14D546-DF.zip
Item4 = EA5T-14F496-AE
Open4 = SyncMyRide\EA5T-14F496-AE.zip
Item5 = EA5T-14F497-AE
Open5 = SyncMyRide\EA5T-14F497-AE.zip
Item6 = EA5T-14D546-AJB
Open6 = SyncMyRide\EA5T-14D546-AJB.cab
Item7 = EA5T-14D546-AGB
Open7 = SyncMyRide\EA5T-14D546-AGB.cab
Item8 = BT4T-14D546-EE
Open8 = SyncMyRide\BT4T-14D546-EE.cab
Item9 = EA5T-14D546-LB
Open9 = SyncMyRide\EA5T-14D546-LB.cab
Item10 = EA5T-14F496-VE
Open10 = SyncMyRide\EA5T-14F496-VE.zip
Options = AutoInstall
[SYNCGen2_3.08.15128]
[SYNCGen2_4.30.13171]
[SYNCGen2_4.31.13319]
[SYNCGen2_4.32.14073]
[SYNCGen2_4.32.14122]
Item1 = EA5T-14D546-AKB
Open1 = SyncMyRide\EA5T-14D546-AKB.cab
Item2 = EA5T-14D546-HB
Open2 = SyncMyRide\EA5T-14D546-HB.cab
Item3 = BT4T-14D546-FB
Open3 = SyncMyRide\BT4T-14D546-FB.cab
Item4 = EA5T-14D546-AHB
Open4 = SyncMyRide\EA5T-14D546-AHB.cab
Item5 = EA5T-14D546-ADB
Open5 = SyncMyRide\EA5T-14D546-ADB.cab
Item6 = EA5T-14D546-AEB
Open6 = SyncMyRide\EA5T-14D546-AEB.cab
Options = AutoInstall
[SYNCGen2_ALL]
Item1 = BT4T-14D546-EE
Open1 = SyncMyRide\BT4T-14D546-EE.cab
Item2 = EA5T-14D546-NB
Open2 = SyncMyRide\EA5T-14D546-NB.cab
Options = AutoInstall
This makes sense to me. It seems as though the car's computer, when it first starts reading the contents of the USB drive should be reading the Autoinstall file and following the instructions baed on the version it encounters. It seems to me that since I'm getting the error message right off the bat, it's having trouble reading the Autoinstall file.
Does anyone think I should edit the Autoinstall file and re-establish the SyncMyRide folder?
Any thoughts here or ideas of how to actually talk to a tech at Ford who would know what I'm dealing with?
I'm hesitant to go to the dealer and be charged to have them face the same issues and my have to pay them to go through what I've gone through.