I want to say thank you for making this video. I never new what a fuse box looked like inside and certainly would not have attempted to take it apart without seeing this done. My ford had the same issue and I successfully took it apart and fixed er up. Thanks again. I will make one comment for others who are going to do this. I did this in reverse order, meaning I set each panel on top of the other so I could set the metal pieces in place without flipping them over. You have to snap each metal piece in place and that is much easier to do if the black insulator panel is set in place first. This way was much less of a fight for me. Cheers.
Excellent video - I especially needed help with removing the fuse box/GEM. I found one small enhancement for your consideration - remove the lower driver's side kick panel to allow access to one more bolt that holds the metal bracket. Removal of this bolt allows an extra 1/2" that is helpful when removing (and especially when re-installing) the fuse box/GEM. Thanks for your help.
Thank you for your work on this video. My 2001 was having problems similar to your video. Took out the fuse box and didn't see much corrosion. Then looking closer at fuse block found some green stuff. Followed your instructions on how to disassemble the block and found water inside. Thank you once again. Now time to have the windshield fixed
A very annoying issue to have and too bad these trucks have this issue. But if you know how to fix it it's not all that bad in the end. The trick here is to catch it in time, before it ruins things.
Dude, thank you! Your video showed me how to fix the problem myself, saving me $800! Thanks for taking the time to make this video, I really appreciate it.
As an engineer and mechanic, I feel that *ALL* engineers should be made to service the devices they develop and package. I realize that there are multiple teams at work in projects like this too. They should all work together to see to the serviceability of their joint creations. I will be servicing the GEM in my 97 F150 for the second time and being in my 70’s now doesn’t make this job any easier. I will be looking to pack this area with “potting gel” that’s commonly used in electronics. Thanks for your tutorial on the process..
@Big-Foot-Randy i agree with you, but unfortunately that isn't how everyone thinks. Glad this video helps out! It's not an easy task and not a quick one either. Also very annoying that this is an issue to begin with, all because of a bad windshield seal.
bought a used GEM a while back and the 4x4 worked once since I installed it. Among other things not working properly. Just bought a used fuse block and will be taking it apart this weekend. I have already cleaned and inspected my original GEM. Going to rebuild the new block this weekend and mount the old GEM to it before I take out the one that's in there. I believe some ppl might be replacing GEMs when in fact it is the fuse block. Great explanation of the whole process. New sub. Thanks for precise instructions. Then a new windshield.
@tedross2424 These issues can be tricky to diagnose and just as difficult to repair sometimes. But the best thing you can do is take it step by step and keep it simple. Think logically, where does the power come from, where is it supposed to go, and when is it supposed to power on and off. Then, why isn't it doing what it's supposed to do? If you think you pinpointed your issue, go for it and fixed whatever you think needs to be fixed. Hoping this time around your repair will be successful in solving your issues for good. And yes, new windshield. Or at least lay some silicone down along the top where the seal usually leaks. That's what i ended up doing. It's been almost 2 years and not a drop has leaked.
man im glad I came upon your video my truck was trying to start any time I would turn the headlights on no radio no heater panel now i know what im up against great job great video you have a lot of patience and a good memory and to ad it was rainy when this problem occurred
I’ve got exactly the same problem with my 2003 Triton model. The only difference was it burned my starter running with the engine while in an ON position. Very wierd. I thought it was a faulty ignition switch and ignition cylinder which I replaced but man, I still burned 2 starters in one day trying to fix it, so I ended up making a separate toggle switch for my starter motor😁😁. Thank you for your patience making this video. 🙏🫶🫶🫶 New subscriber here.
Wow, that's crazy but I'm not surprised. I was afraid something like that would happen to mine if I didn't fix it quickly. But good call on the manual starter switch hahaha
@@AutoFixYT I think I'll have to pull the fuse box out open it up and take a good look at it. My wipers don't turn off and the AC blower stays on after a heavy rain. I'm suspecting its this box is getting water in it.
Thank you so much for the amazing video, I purchased a new gem module and interior Fuse box off eBay and it fixed all my issues, I was unable to get my truck out of 4lo until now! Thanks again!!
Great video !! I had a lot of the same issues on my 99 Expedition. Car tried to turn itself on, and burned out the starter, dash lights wouldn't turn off, wipers going crazy, same speedo issue as you! Battery kept going bad when the car was off. Finally took it to an auto shop to see where the parasitic draw was and it was the GEM module! All makes sense now. I'm glad I figured this out in summer so I can work on resealing the window before winter comes.
Above and beyond average mechanicing I was very impressed! Thank you! So it looks like GM modules may not actually be the culprit but the fuse circuit capsule!
@@petrokrasnov2967 Thank you! And well... the true culprit is actually the windshield leak. That's where it all started from. And then it got into the GEM.
Great video! Thank you ! I followed exactly what you did and now everything is functioning as it should. It took me a few hours to take it apart, clean and reassemble. It was surprisingly fun to do. Thanks again.
Thank you. You saved me a lot of trouble. I was having same problems my windshield leaked a few years ago i thought i got lucky. When i got all the corrosion fixed started blowing fuse for the radio and dome lights.Found the under the hood light was causing that.
I have the exact same problems and plan to get a used fuse box from a salvage yard. This video is the best on exactly how to remove the fuse box and GEM, excellent explanations thank you so much!
Awesome, glad it helped! Yeah get a good fuse box in there if yours I'd bad. Also, make sure you seal the windshield so it doesn't keep getting water in there lol
Good job dude... Make sure the gasket at the back of the hood/ fire wall is sealed across it's full length, and drill 2 1/8 weep holes at the bottom of GEM module so water can escape, if it finds its way back into the GEM again eventually, it will.. btw the glass installation of the rear window, and the windshield, are notorious for leaking due to improper amount of sealant used at the factory, on the 10th gen trucks in particular. Great job, and great video too. ✌️❤️😁
Good ideas, thank you! So far it's been just over a year and no water yet! But I do have to reseal the rear window lol, it's covered with tape at the top right now. Looks like trash.
My 99 F-250 is intermittently having similar issues. I have noticed a small drip near the fuse box too. From the looks of it, the fuse box and GEM are very similar. I'll keep you posted on if this fix is applicable to the Super Dutys too. Excellent video man. Keep puttin' em out! I'm sure you've got a lot of hours into editing/shooting and it shows.👊
I would bet that you're having the same issue even though it's not the same truck. It sounds too similar to be anything else. But yeah keep me updated! And thanks! I have a couple others planned so stay tuned I guess haha
I'm glad it helped! It's a very annoying issue and too mad that it affects these trucks like this. On mine it aurally rotted the floor board from having water dripping on the carpet
I’ve been having the same exact problems with my 1998 f-150. You went very in-depth and I really appreciate that. I’ve been pretty much freaking out cause this is my only vehicle to get to and from work. So as soon as I get home tomorrow I’m going to do exactly what you did in the video. I will follow up in this comment section to let you know if it worked. Fingers crossed. Thank you for taking the time to post this video.
Thank you! And I'm glad the video helps! Yes definitely let me and everyone else here know what you found and whether it fixed it or not. If you choose to disassemble the entire module like i did just take your time so you don't break anything or lose any little pieces. The trickiest parts were drilling out those inernally threaded bolts/studs to get the module apart, as well as disassembling and reassembling all the panels/layers of the GEM. That was also the most tedious and annoying part. My finger tips hurt so bad halfway through from pressing the conductor plates back on that I started having to use pliers. You can do it!
My 1999 Epedition had same issue. I replaced the GEM with a rebuilt one. Still leaking around the top of windshield; keeping it tarped until I can get it replaced. Coastal Oregon is really wet. Thank you for the video; as well done as any I have seen. Fun music and sound effects are helpful. The new module plus labor was over $1000. Bad elect design, I surmise; but I do love the way the Expo rides. Really comples GEM design.
Yeah, still have a parasitic draw with 2 circuits, will fix those. Crazy stuff when that electric brain starts shorting out. It would have been just as much to fix it like you did. Many hours of labor. The video was really high grade.@@AutoFixYT
@DavidMiller-bp7et Yes it took me a few hours in total for sure. But since I had the time and I had all the tools I saw this as a free fix, as opposed to several hundred to replace the module
My great mechanic goes at $100/hour so it gets close to a grand anyway. This seems to be a common issue with Fords of this vintage. I found the 2 circuits with parasitic draws, one of them, #15, includes the GEM. Hope it's something else on the circuit which is crowded. #16 looks easier with less stuff on it. If I had unlimited time and didn't need this as a 2nd car I "might" have undertaken it. Thanks for your very sensible comments.@@AutoFixYT
Yeah $100/hour is typical, sometimes actually on the lower end of rates depending on where you live. Hopefully you can get those parasitic draws fixed!
I’m in the process of of doing this now. I’ve come across a couple of prongs or whatever you would call them that are chipped or burnt…is it a waste of time for me to continue? There is so much corrosion in mine it’s no wonder my truck wouldn’t run right
@flynn1727 if it's really bad your better off sourcing a new one and opening that one up if you think it needs it. Because with that much damage in there you risk it not working properly after you put it back together. A junkyard is your best bet, or a part-out truck.
WOW I thought your video on rebuilding the PSP for the Honda was intense this was a just bananas! I have to give you an A+ for patience my friend. When you were doing and undoing the metallic leads, yeah I would have lost it! 😂😂
Haha thank you! This was an experience for sure! I learned how fuse boxes are assembled haha to be honest, I had no idea it was layered like that until I took it apart. But hey it fixed my issue and I even saved the old fuse box!
Great video my wipers just quit after a pile of snow melted off my truck plus some other electrical quirks... my windshield frame is kinda rusty and fuses had a patina on them all kinda brownish but none were blown. Gonna be looking at this next. Got some roofing silicon that should fix up the windshield frame.
I had a similar issue on my 2003 expedition, it seems like most 1997+ ford trucks that have had the windshield replaced have water intrusion issues (I've owned 4)
Hey! I use the same battery positioner tool you do! LOL. Great video! I have my GEM/fuse box out right now, but no sign of water. Am tracing down a parasitic drain when truck is off. Odd, it goes away if I remove two fuses from the GEM, but one at a time... either one... and the drain stays there. I started to take the fuse block apart, but didn't. Your video gave me confidence to try again. T-Y.
Thank you! As for the draw, it's always annoying to figure this stuff out... keep in mind draws can take a long time to settle down to a number. Thankfully these trucks are old-ish and simple so there aren't many electronics that should run in the background.
Super awesome video!! My question is how long did this whole process take you? I have a 97 with numerous oddities like door dinging when no key in ignition, no wipers, no radio. Thanks for the great video!!
Great video. Cant get my tail lights to work in any way 1999 ford f 250 super duty. I found today when i tested the fuses in the cab with a tester this time instead of just looking at the fuses i found 2 were dead. so i put in 2 new fuses and they tested dead also, and all the other fuses on the panel were okay ........Anty ideas , would appreciate ur opinion. Thanks. .
That means something is wrong before the fuses and they're nit being supplied power. So at this point you'll want to test wiring harnesses, and the best way to do that is with a wiring diagram. See if you can find one online.
I just dismantled and cleaned all the parts to the fuse box on my 97 Eddie Bauer. Couldn't have done it without watching you do it first, very grateful for this video! One question - did you just use the silicone spray in between the panels? I've got all mine assembled and ready to put back together, just curious on how to best go about keeping water out for good(windshield is already sealed).
Thank you! I did use silicone spray between all the layers, yes. But that was just an extra safety layer and also to prevent corrosion from humidity in the air. If your windshield was already properly resealed, no water should get in to the fuse box.
@AdamGainer Silicone is the backyard way, remove and reinstall is the correct way. I went the silicone route. Worked very well. Doesn't look pretty if you look close, but I was going for function over form on this one. I lifted up the old rubber seal where I could, used compressed air to clean and dry, and I went outside on a hot summer day when the truck was baking in the sun so i could ensure there was no moisture stuck in there, and i lathered everything in silicone underneath the seal. Once underneath was full, i played the seal down and finished it up on top. Done :)
I don't think plastic wrap is a good idea because it prevents air flow. Spraying the internals retains the air flow and cooking properties as it was designed, but adds a layer of water resistance that wasn't there before. Also, like I said, ideally you wanna stop the leak in the first place.
Excellent video! The Side-View Mirrors and Driver's Seat Motors stopped working some weeks ago on my 2000 Excursion. Both are powered through the GEM but go through the USM (Under-Seat-Module) for their 'Memory' functions. All connectors are in place. ARRGGG! Double ARRGG Even!! What's a Guy to Do? I really don't want to disassemble the GEM, like our great poster did, but I will if need be. Several years ago, I repaired a Corroded-Thru Ground-Wire that powered the USM to get the Power-Seat to work. Maybe I'll luck out again with a similar wiring problem......
Unfortunately the best way to go about this is to test for power in different places to see where you are losing power. Fuse, relay, GEM, USM, grounds, etc.
Yup. You're Spot On Sir, and that's how the USAF taught me how to troubleshoot the Titan II ICBM Launch Control System 60+ years ago and that's how I fixed the 2000 Exploder's Power Seat 7+ years ago. The seat is where I originally positioned it, and it can stay that way for ever more. The mirrors are positioned for driving, but I like to angle my side out when merging into traffic and down when backing. I've had more pressing problems/projects than this one, but it's now been elevated to #2 on my 2Doo-List. Thanks for your reply. You are exactly correct, and I'll do just that after I move all my Stuffs from my old storage facility to my new one........
I've had weird problems like this exactly all of what you have and also sometimes in heavy rain my starter motor will spin up with my keys in my pocket.
Agreed, you have to have some knowledge as to what you're doing and lots of patience with this one. But for me it was the only option. Plus I was able to film it and share this with everyone because I knew there were many out there that needed help with this. I did too. But I had to compile my own information from many sources, and put it all in this one video.
I'm still stuck on getting the fuse box to slide down as I write this, and have wathed this video over and over in that part, you don't show what you are unplygging from the back to make room for the fuse box to slide down. I'll figure it out, but I don't unplug stuff that I can't see...I need to know so I can make sure I plug stukk back in right. Video helps more than others, thanks.
I just watched the video and it seems to me that i showed everything you need to disconnect to get this out. It was however a very tight fit, and you have to make sure it's not getting caught on any wires in the back. On the back side the only two connectors I disconnected were the two main harnesses with the 10mm bolts. On the left side you have three plugs, and on the bottom there are some retainers to pop off for other wires. That's about it. Other than that it's all about how you maneuver it out of there.
Ohhh boy this should be fun. My 2002 F150 was leaking through the front windshield after a windshield replacement. Relay #1 keeps glitching out with the interior lights and who knows what else. I saw in a comment you said it might need to be reprogrammed if swapping the whole box from a junkyard? Is that correct? But you also said pulling a part would be easier? So should I tear it down or could I jusy plug n play a new box from the yard?
Reprogramming may not be the case on these, although I did read something about it somewhere. So I cannot tell you 100%. If it were me I'd just take my existing one apart because a junkyard one could have the same issue. But yeah either way the issue is very annoying to deal with.
I read there is a seam seal on the driverside that tends to leak. Its under the wiper grid. It starts up at the bottom LH corner of the windsheild and runs down the fire wall.
I would recommend a good electrical contact spray cleaner that will clean and lube your electrical contacts and protect them from further water damage. For those who don't want to repair that thing yourself a place called MODULE EXPERTS will repair and rebuild it for 149 dollars plus 15 dollars for shipping. It will have a life time warranty.
You dont have to remove the knee panel. You can just remove the bolts on the face, e-brake, and hood latch. You can carefully remove the fuse box and GEM module without disassembling so much of your dash.
@@AutoFixYT I sure am glad you responded.I didn't realize I had so many spelling errors in my original comment. I didn't type that, I was hacked..... 😂🤣😂🤣
hey, do you know what the part number was on this fuse box? im having the same issues and im just going to buy a new one but i cant find a part number on google or anywhere.
Wow... what a PITA. You have way more patience and persistence than I do. What a weird design and bad accessibility. I see where they were going for low cost and low IR drop with stamped metal conductors but there must be a better way.
It is what it is, that's all i can say haha I bought the truck, I needed it, and I had to do it. I did not have another option. But yeah it was an annoying process.
I found the leak by digging around and looking for it. I also looked up some stuff on various forums where people described their problem and it lead me to the GEM. No more leaks now!
If you want an amazing battery/connector cleaner try coca cola i did this process and the coke ate through the corrosion no problem, just left the parts in it for a couple hours and didnt do much scrubbing after. Also thanks for the video, couldbr have done it without you
Yep. Coke has phosphoric acid in it. It's the same stuff in naval jelly, which is a gell used to remove corrosion from metal parts. The fizz action from the carbonated water helps too.
There are multiple causes and sources of leaks. The most common issue will be the windshield seal on this truck. They either dry up and stop sealing, or the water pooling up in the roof rails will break through the seal and start seeping in the cab. The right fix is to pull the winshield, clean up the old seal, the potential rust buildup, and reapply new sealant, and reinstall the glass.
I want to say thank you for making this video. I never new what a fuse box looked like inside and certainly would not have attempted to take it apart without seeing this done. My ford had the same issue and I successfully took it apart and fixed er up. Thanks again. I will make one comment for others who are going to do this. I did this in reverse order, meaning I set each panel on top of the other so I could set the metal pieces in place without flipping them over. You have to snap each metal piece in place and that is much easier to do if the black insulator panel is set in place first. This way was much less of a fight for me. Cheers.
That's awesome, thanks for the comment! And I'm glad the video helped!
Excellent video - I especially needed help with removing the fuse box/GEM. I found one small enhancement for your consideration - remove the lower driver's side kick panel to allow access to one more bolt that holds the metal bracket. Removal of this bolt allows an extra 1/2" that is helpful when removing (and especially when re-installing) the fuse box/GEM. Thanks for your help.
Very good tip, thank you!
Your patience for this is amazing.
Thank you! I kind of had to have the patience, i had no other choice haha but I also wanted to show people how it's done.
Thank you for your work on this video. My 2001 was having problems similar to your video. Took out the fuse box and didn't see much corrosion. Then looking closer at fuse block found some green stuff. Followed your instructions on how to disassemble the block and found water inside. Thank you once again.
Now time to have the windshield fixed
A very annoying issue to have and too bad these trucks have this issue. But if you know how to fix it it's not all that bad in the end. The trick here is to catch it in time, before it ruins things.
Dude, thank you! Your video showed me how to fix the problem myself, saving me $800! Thanks for taking the time to make this video, I really appreciate it.
Glad it helped!
As an engineer and mechanic, I feel that *ALL* engineers should be made to service the devices they develop and package. I realize that there are multiple teams at work in projects like this too. They should all work together to see to the serviceability of their joint creations. I will be servicing the GEM in my 97 F150 for the second time and being in my 70’s now doesn’t make this job any easier. I will be looking to pack this area with “potting gel” that’s commonly used in electronics. Thanks for your tutorial on the process..
@Big-Foot-Randy i agree with you, but unfortunately that isn't how everyone thinks.
Glad this video helps out! It's not an easy task and not a quick one either. Also very annoying that this is an issue to begin with, all because of a bad windshield seal.
I was gonna seal the box and the windshield with roofing selant@@AutoFixYT
@big-foot-randy Did you finish your second go round with the potting gel? What did you use? I need to do this job this weekend.
bought a used GEM a while back and the 4x4 worked once since I installed it. Among other things not working properly. Just bought a used fuse block and will be taking it apart this weekend. I have already cleaned and inspected my original GEM. Going to rebuild the new block this weekend and mount the old GEM to it before I take out the one that's in there. I believe some ppl might be replacing GEMs when in fact it is the fuse block. Great explanation of the whole process. New sub. Thanks for precise instructions. Then a new windshield.
@tedross2424 These issues can be tricky to diagnose and just as difficult to repair sometimes. But the best thing you can do is take it step by step and keep it simple. Think logically, where does the power come from, where is it supposed to go, and when is it supposed to power on and off. Then, why isn't it doing what it's supposed to do? If you think you pinpointed your issue, go for it and fixed whatever you think needs to be fixed. Hoping this time around your repair will be successful in solving your issues for good. And yes, new windshield. Or at least lay some silicone down along the top where the seal usually leaks. That's what i ended up doing. It's been almost 2 years and not a drop has leaked.
@@AutoFixYT Any shots of where you laid down the sealant?
My rear glass leaks too, so I am doing that first on the Screw!
man im glad I came upon your video my truck was trying to start any time I would turn the headlights on no radio no heater panel now i know what im up against great job great video you have a lot of patience and a good memory and to ad it was rainy when this problem occurred
That's crazy! If any of the circuits are not good anymore, you'll have to replace the GEM or get another one to piece one good one together
I’ve got exactly the same problem with my 2003 Triton model. The only difference was it burned my starter running with the engine while in an ON position. Very wierd. I thought it was a faulty ignition switch and ignition cylinder which I replaced but man, I still burned 2 starters in one day trying to fix it, so I ended up making a separate toggle switch for my starter motor😁😁.
Thank you for your patience making this video. 🙏🫶🫶🫶
New subscriber here.
Wow, that's crazy but I'm not surprised. I was afraid something like that would happen to mine if I didn't fix it quickly.
But good call on the manual starter switch hahaha
Amazing attention to detail you sir are a real mechanic anyone else would have just thrown a new fuse box in this truck 💯👍💪
Thank you! The way i see it is this repair was free and a new GEM module is expensive lol
@@AutoFixYT I think I'll have to pull the fuse box out open it up and take a good look at it. My wipers don't turn off and the AC blower stays on after a heavy rain. I'm suspecting its this box is getting water in it.
@@paulsosa1872 yup, guaranteed that's what it is
Thank you so much for the amazing video, I purchased a new gem module and interior Fuse box off eBay and it fixed all my issues, I was unable to get my truck out of 4lo until now! Thanks again!!
Awesome! Glad it's fixed!
Best in-depth video on this issue. Well done, and thank you.
Thank you!
Great video !! I had a lot of the same issues on my 99 Expedition. Car tried to turn itself on, and burned out the starter, dash lights wouldn't turn off, wipers going crazy, same speedo issue as you! Battery kept going bad when the car was off. Finally took it to an auto shop to see where the parasitic draw was and it was the GEM module! All makes sense now. I'm glad I figured this out in summer so I can work on resealing the window before winter comes.
Yup those will make the entire truck go crazy! Good thing you got yours figured out!
GREAT video! Really well done. Edited perfectly. Helps solve my problem. Until this, I didn’t have a clue how to fix. Thank you!
Thank you! Glad it helped!
Above and beyond average mechanicing I was very impressed! Thank you! So it looks like GM modules may not actually be the culprit but the fuse circuit capsule!
@@petrokrasnov2967 Thank you!
And well... the true culprit is actually the windshield leak. That's where it all started from. And then it got into the GEM.
Great video! Thank you ! I followed exactly what you did and now everything is functioning as it should. It took me a few hours to take it apart, clean and reassemble. It was surprisingly fun to do. Thanks again.
Awesome, glad the video helped !
Thank you. You saved me a lot of trouble. I was having same problems my windshield leaked a few years ago i thought i got lucky. When i got all the corrosion fixed started blowing fuse for the radio and dome lights.Found the under the hood light was causing that.
Crazy but at least you figure it out!
I have the exact same problems and plan to get a used fuse box from a salvage yard. This video is the best on exactly how to remove the fuse box and GEM, excellent explanations thank you so much!
Awesome, glad it helped! Yeah get a good fuse box in there if yours I'd bad. Also, make sure you seal the windshield so it doesn't keep getting water in there lol
Yup I had this issue. Still haven’t fixed it, glad I found this video
Very annoying issue to have, and definitely fix it as soon as you can! It can damage more things if you let it sit like that.
MAN YOUR NOT AFRAID TO GET INTO IT , AWESOME REPAIR
Good job dude...
Make sure the gasket at the back of the hood/ fire wall is sealed across it's full length, and drill 2 1/8 weep holes at the bottom of GEM module so water can escape, if it finds its way back into the GEM again eventually, it will.. btw the glass installation of the rear window, and the windshield, are notorious for leaking due to improper amount of sealant used at the factory, on the 10th gen trucks in particular.
Great job,
and great video too.
✌️❤️😁
Good ideas, thank you! So far it's been just over a year and no water yet! But I do have to reseal the rear window lol, it's covered with tape at the top right now. Looks like trash.
My 99 F-250 is intermittently having similar issues. I have noticed a small drip near the fuse box too. From the looks of it, the fuse box and GEM are very similar. I'll keep you posted on if this fix is applicable to the Super Dutys too. Excellent video man. Keep puttin' em out! I'm sure you've got a lot of hours into editing/shooting and it shows.👊
I would bet that you're having the same issue even though it's not the same truck. It sounds too similar to be anything else. But yeah keep me updated!
And thanks! I have a couple others planned so stay tuned I guess haha
I accidentally discovered this. I have a 99 + 02 f-150 similar problems. Thanks!
I'm glad it helped! It's a very annoying issue and too mad that it affects these trucks like this. On mine it aurally rotted the floor board from having water dripping on the carpet
I’ve been having the same exact problems with my 1998 f-150. You went very in-depth and I really appreciate that. I’ve been pretty much freaking out cause this is my only vehicle to get to and from work. So as soon as I get home tomorrow I’m going to do exactly what you did in the video. I will follow up in this comment section to let you know if it worked. Fingers crossed. Thank you for taking the time to post this video.
Thank you! And I'm glad the video helps! Yes definitely let me and everyone else here know what you found and whether it fixed it or not. If you choose to disassemble the entire module like i did just take your time so you don't break anything or lose any little pieces. The trickiest parts were drilling out those inernally threaded bolts/studs to get the module apart, as well as disassembling and reassembling all the panels/layers of the GEM. That was also the most tedious and annoying part. My finger tips hurt so bad halfway through from pressing the conductor plates back on that I started having to use pliers.
You can do it!
I have a 05 and my lights come on intermittently, let me know how much of a P.I.A. it was so I know how to spend my weekend...
My 1999 Epedition had same issue. I replaced the GEM with a rebuilt one. Still leaking around the top of windshield; keeping it tarped until I can get it replaced. Coastal Oregon is really wet. Thank you for the video; as well done as any I have seen. Fun music and sound effects are helpful. The new module plus labor was over $1000. Bad elect design, I surmise; but I do love the way the Expo rides. Really comples GEM design.
$1000 is crazy for the GEM. But im glad you got it fixed!
Yeah, still have a parasitic draw with 2 circuits, will fix those. Crazy stuff when that electric brain starts shorting out. It would have been just as much to fix it like you did. Many hours of labor. The video was really high grade.@@AutoFixYT
@DavidMiller-bp7et Yes it took me a few hours in total for sure. But since I had the time and I had all the tools I saw this as a free fix, as opposed to several hundred to replace the module
My great mechanic goes at $100/hour so it gets close to a grand anyway. This seems to be a common issue with Fords of this vintage. I found the 2 circuits with parasitic draws, one of them, #15, includes the GEM. Hope it's something else on the circuit which is crowded. #16 looks easier with less stuff on it. If I had unlimited time and didn't need this as a 2nd car I "might" have undertaken it. Thanks for your very sensible comments.@@AutoFixYT
Yeah $100/hour is typical, sometimes actually on the lower end of rates depending on where you live.
Hopefully you can get those parasitic draws fixed!
The fact you don’t have more likes on this amazes me 🤯 amazing video man
Thank you!
I’m in the process of of doing this now. I’ve come across a couple of prongs or whatever you would call them that are chipped or burnt…is it a waste of time for me to continue? There is so much corrosion in mine it’s no wonder my truck wouldn’t run right
@flynn1727 if it's really bad your better off sourcing a new one and opening that one up if you think it needs it. Because with that much damage in there you risk it not working properly after you put it back together.
A junkyard is your best bet, or a part-out truck.
Yep...so glad i came here....having many of the same things happening...windows, headlights, 4x4 lights. Just crazy.
Yeah take care of it before it gets worse!
Hey, just curious what size is the drill bit you used in the beginning of the video...thanks.@AutoFixYT
I don't remember, but if you have a drill but set I'm sure whatever the largest one is will do just fine. Maybe a 1/2 inch?
WOW I thought your video on rebuilding the PSP for the Honda was intense this was a just bananas! I have to give you an A+ for patience my friend. When you were doing and undoing the metallic leads, yeah I would have lost it! 😂😂
Haha thank you! This was an experience for sure! I learned how fuse boxes are assembled haha to be honest, I had no idea it was layered like that until I took it apart.
But hey it fixed my issue and I even saved the old fuse box!
@@AutoFixYT Great job! Have you had anymore issues with water coming into the truck? Are you going to reseal the windshield soon?
No more issues with the fuse box at all! And yes I will reseal the windshield soon.
Great video my wipers just quit after a pile of snow melted off my truck plus some other electrical quirks... my windshield frame is kinda rusty and fuses had a patina on them all kinda brownish but none were blown. Gonna be looking at this next. Got some roofing silicon that should fix up the windshield frame.
Thank you! Just had to go thru this on my 02’ and this video definitely made it less stressful
Glad it helped! It's too bad these trucks have this problem
Perfect video I just did mine everything works perfect now besides my blinkers
That's usually controlled by a separate circuit, and the flasher relay is under the dash
@@AutoFixYTgot ya still trying to figure it out put 2 new switches in and flasher relay still nothing
I had a similar issue on my 2003 expedition, it seems like most 1997+ ford trucks that have had the windshield replaced have water intrusion issues (I've owned 4)
Yup it's a common thing, I didn't know about it until after i bought the truck
Great video.i drilled holes in the bottom of my gem to help drain out any water as well...
Not a bad idea but better to prevent water from getting in there in the first place haha
Thank you for the video and your hard work. Made my job much easier today!
You're welcome! This was the idea in making this video, to help others solve this problem easier.
Hey! I use the same battery positioner tool you do! LOL. Great video! I have my GEM/fuse box out right now, but no sign of water. Am tracing down a parasitic drain when truck is off. Odd, it goes away if I remove two fuses from the GEM, but one at a time... either one... and the drain stays there. I started to take the fuse block apart, but didn't. Your video gave me confidence to try again. T-Y.
Thank you!
As for the draw, it's always annoying to figure this stuff out... keep in mind draws can take a long time to settle down to a number. Thankfully these trucks are old-ish and simple so there aren't many electronics that should run in the background.
good video sir, when you scary I was like yup I'm on the right video, but my scary was its started up by itself😱
Oh no! That's bad!
Super awesome video!! My question is how long did this whole process take you? I have a 97 with numerous oddities like door dinging when no key in ignition, no wipers, no radio. Thanks for the great video!!
It took me several hours to do it all.
Hope you get your issue figured out!
Great video. Cant get my tail lights to work in any way 1999 ford f 250 super duty. I found today when i tested the fuses in the cab with a tester this time instead of just looking at the fuses i found 2 were dead. so i put in 2 new fuses and they tested dead also, and all the other fuses on the panel were okay ........Anty ideas , would appreciate ur opinion. Thanks.
.
That means something is wrong before the fuses and they're nit being supplied power. So at this point you'll want to test wiring harnesses, and the best way to do that is with a wiring diagram. See if you can find one online.
I just dismantled and cleaned all the parts to the fuse box on my 97 Eddie Bauer. Couldn't have done it without watching you do it first, very grateful for this video!
One question - did you just use the silicone spray in between the panels? I've got all mine assembled and ready to put back together, just curious on how to best go about keeping water out for good(windshield is already sealed).
Thank you!
I did use silicone spray between all the layers, yes. But that was just an extra safety layer and also to prevent corrosion from humidity in the air. If your windshield was already properly resealed, no water should get in to the fuse box.
that was pretty fricken amazing to watch
Thanks haha
My short is off the 5 amp fuse, trying to unplug 1 connection at a time as I test the short.
Any recommendations or tips on how to seal the windshield?
@AdamGainer Silicone is the backyard way, remove and reinstall is the correct way.
I went the silicone route. Worked very well. Doesn't look pretty if you look close, but I was going for function over form on this one. I lifted up the old rubber seal where I could, used compressed air to clean and dry, and I went outside on a hot summer day when the truck was baking in the sun so i could ensure there was no moisture stuck in there, and i lathered everything in silicone underneath the seal. Once underneath was full, i played the seal down and finished it up on top.
Done :)
After replacing I would put plastic wrap and sealer on top of the gem and fuse box to keep water at bay.
I don't think plastic wrap is a good idea because it prevents air flow. Spraying the internals retains the air flow and cooking properties as it was designed, but adds a layer of water resistance that wasn't there before. Also, like I said, ideally you wanna stop the leak in the first place.
Very crappy ford design...Aerostar was the queen B
Excellent video!
The Side-View Mirrors and Driver's Seat Motors stopped working some weeks ago on my 2000 Excursion.
Both are powered through the GEM but go through the USM (Under-Seat-Module) for their 'Memory' functions. All connectors are in place.
ARRGGG! Double ARRGG Even!!
What's a Guy to Do?
I really don't want to disassemble the GEM, like our great poster did, but I will if need be.
Several years ago, I repaired a Corroded-Thru Ground-Wire that powered the USM to get the Power-Seat to work. Maybe I'll luck out again with a similar wiring problem......
Unfortunately the best way to go about this is to test for power in different places to see where you are losing power. Fuse, relay, GEM, USM, grounds, etc.
Yup. You're Spot On Sir, and that's how the USAF taught me how to troubleshoot the Titan II ICBM Launch Control System 60+ years ago and that's how I fixed the 2000 Exploder's Power Seat 7+ years ago.
The seat is where I originally positioned it, and it can stay that way for ever more.
The mirrors are positioned for driving, but I like to angle my side out when merging into traffic and down when backing.
I've had more pressing problems/projects than this one, but it's now been elevated to #2 on my 2Doo-List.
Thanks for your reply. You are exactly correct, and I'll do just that after I move all my Stuffs from my old storage facility to my new one........
Great video, thanks. I would use Corrosion X spray it is made for this kind of work.
@@sut2910 good call, thank you!
👏👏👏great job my friend. You were mine mentor today. Got my gem out today....letts see if I can make it shine...
You got this! Glad this helped!
Where all can water leak from ? Im having the same problems. Are all the 99 - 2004 2WD GEM the same.
Usually it's the windshield. If it's not, then maybe from the cowl and thought the firewall, or through he door harness grommet.
Thanks
@@AutoFixYTdo you know on 99 what year GEMs will work ?
Is the part number on GEM where you can see it without removing it. So i can order one before removing?
I don't know, sorry
Would you work on my 97
@AutoFixYT would you work on my 97
Imgoing through it now wow thanks 03 f150 5.4 v8
Good luck!
Thank you for this video!
Glad it helped!
@ I wouldn’t have been able to repair my GEM without it! Great video and I enjoyed the music as well.
@@BrianBowie Awesome!
Amigo de que año son compatibles las cajas de fusibles, tengo el mismo problema en una f150 2002 2000,2001 2002 y 2003 son iguales?
verifica manual de vehiculo,asumo es lo mismoi
I've had weird problems like this exactly all of what you have and also sometimes in heavy rain my starter motor will spin up with my keys in my pocket.
Yup, sounds like a typical GEM issue. Get that fixed before it catches on fire if it's sparks up in there!
this is not a simple job, many people can not do this
but is a good option to save money. thank's to show
the way to do it,
Agreed, you have to have some knowledge as to what you're doing and lots of patience with this one. But for me it was the only option. Plus I was able to film it and share this with everyone because I knew there were many out there that needed help with this. I did too. But I had to compile my own information from many sources, and put it all in this one video.
I'm still stuck on getting the fuse box to slide down as I write this, and have wathed this video over and over in that part, you don't show what you are unplygging from the back to make room for the fuse box to slide down. I'll figure it out, but I don't unplug stuff that I can't see...I need to know so I can make sure I plug stukk back in right. Video helps more than others, thanks.
I just watched the video and it seems to me that i showed everything you need to disconnect to get this out. It was however a very tight fit, and you have to make sure it's not getting caught on any wires in the back.
On the back side the only two connectors I disconnected were the two main harnesses with the 10mm bolts. On the left side you have three plugs, and on the bottom there are some retainers to pop off for other wires. That's about it. Other than that it's all about how you maneuver it out of there.
Great video, wish i had your patience.
Well... i didn't have another option haha but also it was a learning experience for me.
Ohhh boy this should be fun. My 2002 F150 was leaking through the front windshield after a windshield replacement. Relay #1 keeps glitching out with the interior lights and who knows what else.
I saw in a comment you said it might need to be reprogrammed if swapping the whole box from a junkyard? Is that correct? But you also said pulling a part would be easier? So should I tear it down or could I jusy plug n play a new box from the yard?
Reprogramming may not be the case on these, although I did read something about it somewhere. So I cannot tell you 100%. If it were me I'd just take my existing one apart because a junkyard one could have the same issue. But yeah either way the issue is very annoying to deal with.
Nice video! The windshield is sealed when installed. The rubber trim pieces are just decorative. So, water ingress is likely occurring elsewhere.
Yeah I know. But I lifted up the rubber seals and siliconed underneath them. Problem solved for me.
I read there is a seam seal on the driverside that tends to leak. Its under the wiper grid. It starts up at the bottom LH corner of the windsheild and runs down the fire wall.
Could this cause fuses to smoke and no brake light
Yes it can
I would recommend a good electrical contact spray cleaner that will clean and lube your electrical contacts and protect them from further water damage. For those who don't want to repair that thing yourself a place called MODULE EXPERTS will repair and rebuild it for 149 dollars plus 15 dollars for shipping. It will have a life time warranty.
Good idea, if you have that definitely use it!
Many thanks ...I know this is my problem too....u do it i can do it
You can do it!
You dont have to remove the knee panel. You can just remove the bolts on the face, e-brake, and hood latch. You can carefully remove the fuse box and GEM module without disassembling so much of your dash.
Yeah, I kinda suspected that after I took the knee panel off but I was already committed so I wasn't gonna go back. Only a few bolts anyway.
@@AutoFixYT I sure am glad you responded.I didn't realize I had so many spelling errors in my original comment. I didn't type that, I was hacked..... 😂🤣😂🤣
Where are those head lights from
@dirtyoatmeal7377 I got them from 1AAuto.com, they're awesome
hey, do you know what the part number was on this fuse box? im having the same issues and im just going to buy a new one but i cant find a part number on google or anywhere.
I don't have a part number, sorry. Maybe you can source one from a local junkyard?
Ford no longer offers this part.
Part# on sticker on fuse panel. Ebay has these, around $150
Great video man,i just had to do the3 same thing to mine,damm window seal
Yeah, bad design but what can you do…
GOOD JOB!!!!!!
Thank you!
professional!
Thank you!
Wow... what a PITA. You have way more patience and persistence than I do. What a weird design and bad accessibility. I see where they were going for low cost and low IR drop with stamped metal conductors but there must be a better way.
It is what it is, that's all i can say haha I bought the truck, I needed it, and I had to do it. I did not have another option. But yeah it was an annoying process.
this is amazing! How did you find the leak however? Is that still there?
I found the leak by digging around and looking for it. I also looked up some stuff on various forums where people described their problem and it lead me to the GEM. No more leaks now!
If you want an amazing battery/connector cleaner try coca cola i did this process and the coke ate through the corrosion no problem, just left the parts in it for a couple hours and didnt do much scrubbing after.
Also thanks for the video, couldbr have done it without you
I will keep that in mind, thanks for the tip!
Yep. Coke has phosphoric acid in it. It's the same stuff in naval jelly, which is a gell used to remove corrosion from metal parts. The fizz action from the carbonated water helps too.
Let me tell ya.... that module and fuse panel is more of a pain when you have a clutch pedal trying to help fight you as well 😂😅
Yeaaah i belive that! Haha must be 10 times worse
My truck leaked as well I heard it sizzling....😢🎉
Oh no! Fix it before it catches on fire!
So? Ford and other manufacturers go to millions of dollars to design these components and they still LEAK? Design flaw or manufacturing defect?
There are multiple causes and sources of leaks. The most common issue will be the windshield seal on this truck. They either dry up and stop sealing, or the water pooling up in the roof rails will break through the seal and start seeping in the cab. The right fix is to pull the winshield, clean up the old seal, the potential rust buildup, and reapply new sealant, and reinstall the glass.
Ford= fix or repair daily...fix on race day...found on road dead...etc
Lol yeah, not my first choice of vehicle but the opportunity presented itself and I needed something this size so... whatever lol