Just got a 1997 F150 regular cab, with the 4.6l. I'm well aware of the leaky windshield/GEM and fusebox issue. Today I went to Safelite and had the windshield replaced. The technician told me that my windshield isn't actually leaking ( i call b.s. there is to much oxidation on the metal under the dash) but the rear window was causing my GEM issues ( power window, windshield wipers not working and inside lights and hood lights stay on. Its obvious that the rear window had a leak becuase someone has tried to silicone the seal. Thoughts?

 

I also have those problem on my 98 F150 Extended cab. I solved the leaking rear glass using a silicone sealant. The back seal was so deep, I used a syringe with big needle and the widest screwdriver to spread the silicone. Actually it's the rust and corrosion on body ground causing the electrical issue.

 

So you're saying the rear window leakage could cause the gem/fuse box issue by oxidizing the metal and messing up the ground? Hmmmmm interesting

 

Had same issue. Safelight is a waste of money. Sorry to say. I took my truck after same procedures as yourself to the body shop and he said " people never learn, it's a body defect " so he took the front / rear out and resealed them with industrial silicon. He charged me $50. for having sympathy with my week of hardship this had caused. Try a reputable shop. Will not fail if done right

 

Appreciate it man.

 

I don't know if you are referring to same leak that I had on my 03, below is the link that fixed mine with a butyl tape $20 fix from NAPA. GL
https://www.f150forum.com/f6/water-c...in-top-211829/

 

It's not a body defect. According to the TSB the 97-98 Expedition, F150, F250 LD Water Leaks in various area of Windshield, Cowl Top, Cowl Side to Door Opening Panel, Cowl side to Dash panel is causing electrical concerns such as warning lamp illuminating, improper wiper operation, and improper function of electrical accesories. The Water leak was caused by Sealer Skips, Unseated Grommets & Clog Drain tubes.

 

I went on ahead and replaced the GEM. Everything came back ( well for the first time for me). Hopefully the safelite repair holds up and no leaks. I have to work on the back sliding window somebody previously siliconed it and I mean they didn't even come close to making it look oem. They just globbed it on there ( no leaks though)

 

I still have problem on my cowl panel. The glossy black is peeling off. Any idea how can I stop or restore it?