Chad81

I was getting ready to leave work today and she wouldn't start up had plenty of juice from the battery. I had my spare tire off because I've been cleaning the rim up to paint it, so I had easy access. Crawled under and had a look, noticed the module was arched in the shape of a V on the side the connector seats in. Autozone was 2 minutes away so I picked up a new module that came with rubber spacers to allow drainage.

I unplugged the old, plugged in the new and she started right up like normal. I only had to drive 5 minutes to get home so I drove home with the module tucked above the frame. I removed the old module and it looked like pictures I've seen here in the past. The portion that seats against the frame was completely corroded and a good inch broke off the end leaving the internal circuitry exposed. I installed the new module with the spacers that give a good 1/2" of clearance between the module and frame, hopefully that will extend the life of the new module. I really should've inspected it when I dropped my spare recently, I paid for it!

The old module looked like this :

joe mcmillan

Looks bad. How much you pay for the new one at Autozone?

Chad81

$64

joe mcmillan

Fair price for need it now.
$54 on Amazon but you get it next week.
I was lucky when I checked mine. It was still like new so I removed it, painted it with several coats of epoxy. Put fiber spacers behind it so it no longer touches the frame.

Chad81

It was an oversight by the Ford engineers allowing two dissimilar metals like that to contact each other, the original design should've included rubber spacers or something similar to keep the module from contacting the frame. That was a good move on your part painting the module and spacing it from the frame, it will save you money in the long run.

jagsfan

Galvanic corrosion. Aluminum and ferrous metals don't play very well together.