Ford Engineers have in fact developed an improved program - they put it on the '06 models. My dealer told me that the programming is identical but they are wrong. The '06 and the '05 behave quite differently when it comes to EV mode operation. They are also different in how they behave during deceleration in "L" - the 4000 RPM I get in the '05 is more like 2500-3000 RPM in the '06. I read somewhere (an email from Ford) where the engineer said they toned it down some.

So, there are differences in the programming from the '05 to the '06 and from what I have seen (I have about 10k driving each one) the '06 is a big improvement. My mileage is better in the '06 too. If I ever find out they can reflash the '05 to the '06 program, I'll be first in line.

You from Boston, bostondick?