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Old 06-08-2011, 05:48 PM   #1
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Default The leaky windshield/GEM module problem, with a twist

Last year, I started having trouble with my lights turning on randomly, then the radio was acting weird, etc. After doing the research, it sure sounded like I had a problem with my GEM module. After I replaced it, all of my problems went away and I thought 'problem solved'.

Well, last week the issues started up again. Lights randomly coming on, etc. I decided that since the last time I didn't get my windshield re-sealed that I likely had the same issue and would go ahead and get the windshield re-sealed this time before I put in another GEM module.

The problem is, the auto glass guy said my windshield was perfectly sealed and there was no reason to replace it. My question is, what else could possibly be causing this problem? Do I maybe have a bad computer? Am I getting a leak from somewhere else? Do I have a bad wire somewhere?

This thing is really confusing the heck out of me, and help would be appreciated. It's a 2000 F150 4x4.
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Old 04-28-2012, 05:40 PM   #2
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Dec 2011 First got the airbag light and code 5-2. Then my batt would drain and die overnight. Installed new battery -- same thing. Then the weird stuff started: dome light wouldn't turn off; headlights wouldn't turn off; engine surging or no acceleration; chirping sounds from inside dash; speedometer dropping to zero -- and none of these things were consistent. They occurred randomly. Only thing that was persistent was the airbag light and code.

In Jan 2012 did the AutoZone checks - came up normal. Took it to 2 different garages - they said $75/hr to run down the obvious "short to ground" problem (and that could be hours to days to do!!!).

In Feb I read on here about the windshield leaking problem that Ford refused to do a recall over. I took it to a window and glass place that mainly does auto window repair. Sure enough - my windshield showed definite signs of leaking once they had it off. They cleaned and resealed within a couple hours. ($85).

******** ALL ELECTRICAL AND ENGINE PROBLEMS DISAPPEARED !!!!!!!!!!!!!!

246 Starter cycles later the AIRBAG LIGHT AND CODE WENT OUT!!!!!!!!!!!!!!!

So for $85 my 98 f150 runs perfect after 2+ months of frustration. And I saved hundreds of dollars from having a mechanic run down an electrical short that never existed! It was all due to moisture from a leaky windshield!
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Old 05-10-2012, 04:45 PM   #3
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Quote:
*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 STAYING ON AFTER DOORS OPENED AND KEY OUT OF IGNITION, WIPER CIRCUIT FAILURE CODES, AND MULTIPLE SYSTEM WARNING LIGHTS WITH 'SHORT TO POWER' OR 'LOW BATTERY VOLTAGE' DTCS. THESE SYMPTOMS MOST OFTEN OCCUR AFTER A RAIN OR SNOW.

THIS MAY BE DUE TO GEM/CJB WATER INTRUSION RESULTING FROM A WINDSHIELD WATER LEAK. TO SERVICE, REMOVE THE GEM AND CJB FROM THE VEHICLE, SEPARATE THEM AND INSPECT FOR WATER CONTAMINATION OR CORROSION. IF FOUND IN EITHER COMPONENT, REPLACE BOTH COMPONENTS AND COMPLETELY RESEAL THE WINDSHIELD.

EFFECTIVE DATE: 04/05/2002


This notice was sent out to all ford dealerships and they know of the issue, the correct fixing procedures is replace the GEM module, inspect the fuse block and replace it if necessary, and remove and reseal the windshield, which usually results in a broken windshield, so a replacement may be needed. This also now includes F-150's up to 2003 and several other Ford models from the same years.

Ford will not recall this until many die because of it and it hits the new's like what happened with the rear axles on the Windstar after many people have lost their live due to this issue.

I had my GEM module have issue while I was driving on the highway and I had my windshield wipers stop working, my radio started bugging out. Though it only lasted for a few seconds, going 70 MPH on the highway during heavy rain during dusk scared the crap out of me, I ended up cracking my windows and turned on the lower vents on full blast heat until I could make it back to my house. After I did research and found out this is a issue that ford claims is not a manufacturing defect, its just a defect that shows up a few years after been sold and weathered, as they told me a year ago.
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Old 06-15-2012, 04:57 PM   #4
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my 1998 f150 done same kinda thing it was gem but its not the windshield you will probably find your problem if you open hood and the plastic that catches windshield water run off is loose instead of water running onto it and down the side it is slightly raised and the waster running down windshield is actually running under black plastic it has sticky foam under it the foam can rot away and the water will run right down the firewall and right to your wire harness plugs right into the fuse box and gem hope this helps
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Old 06-16-2012, 12:09 PM   #5
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Quote:
Originally Posted by squirrel View Post
my 1998 f150 done same kinda thing it was gem but its not the windshield you will probably find your problem if you open hood and the plastic that catches windshield water run off is loose instead of water running onto it and down the side it is slightly raised and the waster running down windshield is actually running under black plastic it has sticky foam under it the foam can rot away and the water will run right down the firewall and right to your wire harness plugs right into the fuse box and gem hope this helps
I just had the work done to my 2003 F-150, had the GEM, Fuse block and the windshield replaced/re-sealed, and it was the windshield. All under the windshield was starting to rot away. They were able to grind off the rust, and re-seal the windshield and do everything else for about $1400. Overall, the safety issues that comes with this known problem should make it something ford would want to fix, but in their own words to me, we wont fix it unless they are forced to do it by NHTSA.
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Old 01-10-2014, 06:30 PM   #6
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i have had this problem changed gem and fuse box repair lasted 6 months
dealer never told me i had a leak thanks . i have learned a lot on my own a temp fix is to use compressed air to dry out uplug back of gem and apply dielectric grease on them plug back in i will have to find this leak there is an after market gem guaranteed to be water proof this problem is in my 2002 f150 4x4
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Old 01-11-2014, 07:55 AM   #7
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For those who've posted, my issue was solved by sealing the wire harness and it's entry point into the door panel. I went through two GEM modules before noticing it loose. I've had no trouble for 2 years now.
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Old 01-11-2014, 07:12 PM   #8
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Well, its been about a year and a half since the issue, Replacing the windshield, GEM module, and fuse block was what I had to do and has been working great. I found out that my friend that has a 2002 F-150 has the same issue and was due to the windshield like me.
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Old 03-04-2014, 01:56 PM   #9
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Im having the infamous leaky windshield issue. I ordered the aftermarket gem, and still had the phantom electrical problems. Radio on off, stater going on by itself etc. It finally went away for a day and then i hit a rainstorm and shazam, it sterted going crazy again. Wipers stopped and i was blinded.Almost hit another car until i finallyh pulled over and the box started smoking and i couldnt shut it off. With ignition off, i put it in gear and finally shut off. No, i hadnt replaced the windshield yet as that was next.
I gotta say that was the most hair raising experience i have had and never want to repeat. I,m wondering if the fuse block was defective too because i dont know why it was still doing it. Instead of going through all of that again i,m gonna sell it for parts. It amazing that Ford would let this problem go on like this. I was almost a statistic. I guess that is what it will take.
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Old 03-04-2014, 02:22 PM   #10
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Yep, a known issue. My '02 had it too, had to pay $140 to have windshield resealed. Ford acting this way is what makes me not want to buy another one! Knuckahaids.
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Old 03-04-2014, 02:22 PM
 
 
 
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