Expy has serious electrical problem

[mesipu69]

I have a 2001 Expy and I am having problems. Three times in the ast couple of months I am out and go to start my expy and it won't fire. It goes to turn over and then nothing. The battery is fine, the first two times it started by waiting a few minutes, and then the second times touching the fuse panel under the hood. Today it just won't start, we have had alot of rain lately and I am not sure whether its the same kind of problem yous are describing. What does that GEM module look like? Can anyone help? Please?

[Freddi63]

Checked posting from gobzofzeal titled "HAZARD!! Electrical/windshield F-150 Expeditions navagators 1997-2003" for the solution and below is the message from Ford gobzofzeal posted. Don't know if the dealer will fix for free but will call to get information on repair options. But am glad I am not the only one that is having this problem. Started having this problem about a month ago and could not figure out what was going on. It's raining outside this morning and it happened again. Decided to search the internet for a solution and here I am. Thanks to everyone, I am glad I am not crazy and the prossession of my 2001 Expedition has been solved. And thanks to Petrina Compton for finding the Ford information that is greatly needed. Again, Thanks.

Here is the message sent directly from Ford to all Ford dealerships in April 2002: *FORD SPECIAL MESSAGE #15773 VARIOUS ELECTRICAL CONDITIONS RESULTING FROM WATER INTRUSION INTO THE GEM/CJB SOME 1997-2002 EXPEDITION AND 1998-2002 NAVIGATOR VEHICLES MAY EXHIBIT VARIOUS UNUSUAL ELECTRICAL CONDITIONS, INCLUDING BUT NOT LIMITED TO: FRONT OR REAR BLOWER OR EATC STAYING ON WITH KEY OUT OF THE IGNITION, RADIO

[dtbartle]

I am having the same problems. I was here on this forum yesterday and read the posts about windshield leakage and thought, well that's not it, my windshield hasn't been leaking; however, I just got a call from my Ford dealership (where my 2000 Expedition has been since 11/2) saying that they have replaced the GEM but now the fusebox needs to be replaced due to water leaking through the windshield. So they want me to grant them permission to replace the fusebox and reseal or replace the windshield. For now I've told them to hold off and not do anything else. Has anybody had any luck getting Ford to pay for this? My repair bill so far is $744.00!! Also, have you all filed complaints with the NHTSA? NHTSA Defect Investigation #EA05015. Thanks in advance for any help! Donna

[clark0505]

Sorry, I don't have a solution to your problem but I wanted to say thank you for all that you do. I will be praying for you and your family and I hope all will be well.

[Hubble73]

I have a 2000 Exp the wipers will come on when you start the truck, the odemitor will not light upsome times and the truck will just shut off while driving down it was just shuting offf on long trips now it shuts off every five to ten minutes. Has anyone had this experice related tto the Gem Module? the shop says it is electrial but they don't know where?

[kris363]

My HVAC blower comes on after I stop the engine, and I have finally figured out that it is a leak. I haven't seen the leak, but the dealership readily agreed that my GEM would have to be replaced because of it. We need to find a way to get the Ford dealerships to pay for the leaky windshields. Go here: http://www-odi.nhtsa.dot.gov/ivoq/ to make a complaint. Right now, they "only" have 39. Make sure you mention words like "could possibly cause a fire" or "unwanted electrical activity when the car is unattended" so they see the seriousness of the problem.

I told my wife we should have gotten a mini-van!!

[kris363]

I went down to the dealer to see how they fix the windshield leak. We just had a big rain last night here in Houston, and I forgot to cover my truck. Battery was dead this morning because the HVAC blower and radio went crazy last night. Got it jumped, can drive it. Windshield wipers will only work in Park, and radio turns off suddenly. HVAC blower turns on after you remove the key. I disconnect terminal from battery when I park it. Once it dries out, it is fine (I don't think my GEM Module is bad).

I talked to the glass guy at Ford dealership. I told him I want to do it myself, and he kind of scoffed at me...maybe because I was wearing a suit and tie. He sold me a tube of urethane auto glass sealer and gave me a little tool to spread it around the windshield.

Once I finish the windshield I will come back and let you all know how it went.

One more thing...the told me that Ford will take care of this for free if you have less than 75000 miles. I have 94K...that sucks!!!

[crgbrault]

Just had same things happen to me on my Expo. It only has 63,500 mi. I do almost all of my own service work and called my local dealer and talked to the service desk person. I told him about my lights, wipers, radio, heater, p-windows, p-locks and dash lights all were not working when put I put it into drive he said with out hesitation, gem-module and fuse box would need replaced and windsheild replaced and it would be between 1,000 to 1,300 to fix.
Does anyone know if this is under warranty?

[sdcs2005]

I have the same damn problem. Quoted $1100 to replace winshield, GEM module and Junction Box. This is definately BS. Has anyone found a better repair price away from the dealerships?

[kris363]

If you have less than 75,000 miles, the guy at the dealership said they would take care of it. I have over 90K, so I had to do the following:

At the Ford dealership, I talked to the glass guy, and asked him how he seals the winshield. He sold me a tube of Urethane (made by Dow Automotive) and showed me how to do it. It is a very messy job, but I think I did OK.

Today, I got a quote of $248 for the GEM (part only), and I don't know how much the fuse box is. Went back to the service bays and talked to the guy that does it, and he sold me one of his test units for $50!!! This could potentially get him in trouble, so I can't mention the Dealership name. He told me how to remove the fusebox (with GEM connected). I am going to pull the whole thing out, see if my fuse box is all corroded, and replace the GEM. If I have to go buy a fuse box, I will probably have to get a new one.

I will let you know how it goes? So far I have spent about $70