Expy has serious electrical problem

Hi, I'm deployed in Iraq right now and my wife is having problems with my 2002 Expedition. I only know what she told me so here it goes. The vehicle would not start all off the sudden and needed a jump. Once started there was no problem. She smelled a burning smell from near the radio. she took the radio out to inspect the wires and found nothing. She said the Locks, Lights and Alarm were going crazy so I told her to disconnect the Alarm. There is a continueous "clicking" That we thought was coming from the alarm but found it was coming from the fuse box or in that area. I told her to disconnect the battery just incase and she said the battery terminal was melted. We arestationed in Germany so parts are very expensive and mechanics are even more expensive. just the tow to the shop is $600. my wife is pregnant and I wont be home for a while, she needs the vehicle. Please, any help would fantastic.

Sounds like a similar problem I had with my 2000 Expy EBauer. Ford had a recall related to the windshield wiper motor, a leaking cover let water get in the unit causing electric shortages. With no key in the ignition, the fan blower would run, radio would go on, dash lights would flash, etc. If it rained or was very humid, you could count on it happening. I added a quick disconnect to the battery so if the weather was bad, I wouldn't run down the batter.

Do you have info on this recall. I have a 1999 Ford Expedition and having windshield wiper problems, they are coming on by themself. Have had the speed control problem fixed.

I had the same problems. Sometimes the truck would try to start by itself . I took it to the dealer windshield was leaking and it was causing my fuse box and my gem module to short. $1086.00 to fix. Windshield was leaking driver side on top running down the inside of the"A" post so i could not see the water hopethis helps. p.s. thank you for all you have done for us back in the U.S.

[dragunbomb]

The same thing happened to me.. My husband is also deployed in iraq.. and i had to do deal with this. well i end up taking it to ford. What bughes72 said on his post. they said the same exact thing. with the windshield leakage...but I got a different quote.. its 680.00. with them repairing the leakage from the windshield too. They are ordering my parts now. and hopefully it wont cause any problems.. I hope your wife got her truck fixed..

[PhanFord01]

Hi all,
I have had the same ongoing problems (almost identitcal to bughes 72). I have already had the GEM module, fuse box, and a few other electrical parts replaced. When I had these parts replaced, the dealership couldn't find the leak. After heavy rains here in PA, the symptoms have returned. I am taking it tomorrow to have a Ford collision center find the leak, but I suspect they will want to replace the windshield. I really can't afford to replace the GEM module and other parts again (around $700) on top of having to pay for the windshield repair. It is a 2001 2wd XLT originally from Texas, but now in PA. If the solution is different than bughes 72, then I will post it as soon as I know something. Thanks to all who took time to post.

[attism]

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I have a GEM Module for a 98 Expedition for sale. I bought it from the dealer but could not return it because of opened box. It has never been used.

[bhazell]

I've had the same problems as bughes72. I've had to GEM modules changed before I knew about the leak. My wife and I complained to FORD and they assured me there wasn't a leak but how else does a module get wet?????
Leak is in the drivers side of the front windshield. New problem, truck won't go into gear. Stuck in 2nd gear and key won't come out. Is there a release like the newer trucks? I hope it's not the transmission, I just hit 100k and I didn't get the check engine and the truck has been maintained fairly well.

[sbjb]

I had the same problem on my 2000 expedition.
It rained really hard the other night. I came out and it would not start. Their was a clicking coming from under the stearing wheel. I put a charger on the battery and was able to get it started about 1/2 later. I drove to work and everything seemed fine. Then later the clicking started again when I was going to lunch. All I did was open the door and it was clicking. After I started it and was driving the warning alarm came on as though a door was open. Lot'
s of strange little clicking noises again. I took it to the local dealer. They told me water had leaked into the fuse box and the gem was damaged. They said it was the windshield leaking but could not tell me where. The can not re-seal the windshield according to the dealer so $220 for new windshield plus $700 for new gem/fusebox with labor. $920 total. Ouch. This seems like it's a common problem. Anyone know if Ford is doing anything about it? Even my service guy has stated he's seen this several times.

[David Huggins]

2003 Ford 150 has same leak at the windsheild and electrical issues stated. I was told it's not going to be fixed by Gullo Ford of Conroe or Ford Customer Service. The cost is over $1,000.