Ford Sync Can Not Download Update

Hi All,
  1. Ford Sync 3 Update Download
  2. Ford Sync Cannot Download Update Iphone

Quick history. Just got my 2013 Flex SEL that was built in Sept. 2012 so it's been sitting for more than a year. I went to update SYNC this morning and it failed. ON my SYNC update page it shows last update Sept. 2012 so the system has never been updated. (You would think the dealer would do this for you).
I followed all the steps to update; it starts to update, then I get a message 'You have already updated your software..', Then it shows another screen like it's trying to update, then a 4th screen saying installation failed.

Download owner manuals; QUICK LINKS. SYNC software updates. Update SYNC 3. Get more out of your commute with Waze and Alexa. SYNC Connect. SYNC Connect allows Ford owners to stay connected to their vehicles in a way they’ve never been able to before.

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I have followed all the steps:
  1. Jan 28, 2014  Called Ford SYNC support and they seem to think the update was applied at the dealer but that it was never reported which is why it's telling me I need to update but won't let me. Support suggested I run a health report which will automatically update the vehicle record and version number and also check the SYNC version number in the Flex.
  2. R/Ford: Ford stuff goes here. Hey guys, just wanted to update you all on this. The download is available now and I've updated to 4.6. However, I've lost the ability to control the Spotify app (Call it up using SYNC voice commands) for some reason.

1. Download file to HD
2. unzip file
3. copy all files to 4GB USB drive (formatted FAT32)
4. Turn on Flex, engine running
5. Radio on
6. Insert USB drive (Install starts automatically but I get the error sequence above. I posted the screen images below. Sorry, they go by quick so camera focus is a little off.
After the first failure I reformatted the USB and tried from scratch with the same results. Any ideas on how to make this work? There is nothing else on the USB drive. I downloaded and installed on Mac OS X but that shouldn't make a difference.
OK, it won't let me attach photos.
1st screen: Installing file..(1 of 10)Ford sync cannot download update mac
2nd screen: You have already updated your software successfully. Please remove the USB drive.
3rd screen: Installing file..(1 of 10)

Ford Sync 3 Update Download

4th Screen: Installation Failed! The installation has run out of space or does not work with this version.
Anyone knows what my next steps are? Please don't tell me I need to go back to the dealer.

Ford Sync Cannot Download Update Iphone

- Tom