After reading your post, I have two answers for your Item #1:

If this blend door is the one in the front, you can find lots of info here. This blend door is just a funny noise issue that won't affect your car at all (in my experience).

If this blend door is the one in the back, you should replace asap since it affects cooling your hybrid battery. Here's a DIY thread. I just googled for a while and can't find the TSB. Sorry. Hopefully someone here knows. Maybe my memory was bad and my dealership fixed it because it was under warranty not because of the TSB. The back blend door should be covered by the hybrid components warranty. Good luck.

 

No point in making a new thread. I got the SSN today. I was just accelerating from a stop light, doing around 25 MPH and going straight ahead. I pulled over and after a couple of key turns it started again.

I had this issue before and it was the MECS pump, but last time I had a yellow triangle in the center of the dash; this time I only had a red "!" on the right side of the dash, plus the SSN message on the info center. The SG showed no codes.

I guess it is back to the dealer again.

 

A TSB is not a recall. If the vehicle was out of its base or extended warranty coverage, you pay for the part and labor, not Ford.

The blend door actautor is not covered by the hybrid component warranty. That warranty is available in writing and specifies the specific components covered. Many here think that this warranty covers ANY component unique to the hybrid vehicle. That has never been correct.

 

How dirty is your throttle body?

 

I don't know, it is dealer maintained but I don't recall them asking about it.

 

Hello again...
SSN happened twice today...while my wife was driving.
Once she came home, I noticed that fans did not stop running for a while. But after they did stop, I check the MECS pump and the fluid in the rear coolant bottle and discovered it's not working…tapping it with the hammer makes it run!
So I ordered a kit and will wait to replace it!

 

That was the cause of my SSN....there's a TSB on it somewhere.

 

Actually I'm considering trading mine in on a C-Max, but if I keep it I'll mention that at my next service, which would be next week or so. Thanks.

 

Pretty much what I did. Our FEH served us well after replacing the traction battery actuator and MECS Pump, but it was always a bit of a rattle trap. We just bought a 2014 C-Max Hybrid and love it so far. Getting almost 42mpg with only 600 miles on it (I mention because Ford says best mpg is seen after 1-3k mile engine break-in). If the videogame-like readouts are at all accurate it says I've gotten close to 50mpg with some typical hypermiling techniques.

The Ford dealer offered just $6k on our FEH so I sold it private-party a week later on Craigslist for $3.5k more than their offer. Usually isn't worth trading anything in at the dealer.

 

I find the front seat to be a bit more cramped than the FEH, so I passed on the opportunity to buy it yesterday. I probably should have bought it. I still have a 5 year / 48K warranty on the FEH, so I suppose I'll just stay with it.

Thanks for the ideas, though.