Bad news guys, this is not a cheap problem! I took my truck in last night to Valley Ford here in Cleveland. The went ahead and looked at it last night and called saying that they agreed that the GEM was the main focus.

GEM = $200
Programming = $95
Install = Aprox $300
Total was going to be between $500 - $600 w/window resealing

Not bad I thought, I can handle that. So I told them to go ahead and order the GEM.

I get phone call this morning telling me that there is a relay that is not responding, I think no problem, that can't be too expensive, WRONG! If they only replace the relay and the windshield, we are talking about $800! That does not include anything involving the GEM. Apparently the dash is removed in order to get to the relay.

If they find out that the GEM still isn't working once the relay is replaced, my total will be $1200! Ouch! Needless to say, I got the phone call not too long after that (they had a relay in stock) and even with the relay replaced, the GEM was testing with a bad pin (thats what they told me).

I didn't have much of an option than to approve the work, so tomorrow I get my truck back with working 4wd and a sealed windshield. I just payed this thing off 2 months ago!

Oh well. As for the dealership, I have complete confidence in them, they have done a bunch of work for the company I work for and I have some friends that are tight with some of the guys there, so this is legit diagnosis.

If nothing else, I hope that anyone out there that has experienced water leaking on the drivers side floormat will get the problem addressed as soon as possible. I put mine off for a couple of months just because I didn't have the time or money to mess with it. I am paying for that decision now.

Good luck and I will keep you updated.
Joe

 

Well Joe I'm havingv the problems metioned earlier it started with my 4wd. It wouldn't select sometimes but it just went dead one mornming after some rain. Anyways which relay wasn't responding and is it totally ok now cause I getting the speedo going to 0mph and then back up in the middle of traffic. This could be dangerous. How long does it take to get the GEM module changed?

 

Just got my truck back from the dealership.
New GEM: $156
New Fuse panel: $140

Labor to install: $102

Winshield re-seal: $172

As you see this was a costly leak!
Could've been done in 2-3 days if they'd ordered the right GEM, and didn't have to replace the power steering pump as well.

 

Guys, this issue really torques me up! After reading everyone's feedback I went out to test my windshield for any looseness. Bingo, upper-front area easily flexes outward when pushed by hand. I guess I need to go hunting for quotes on the repair. Agree that Ford should take responsibility on the issue since the truck is only two years old. Okay...I'm depressurized now.

 

Well, I am back on the road with my 4wd operational. Its a good thing with the snow we are getting!

On to my point, the total for my ordeal was about $1000. I lucked out and my company had an account with the dealership, so I got a little break (it would have been around $1250+). The replaced a 4wd Relay (line item was F65Z*14N089*AA Relay), the GEM (F85Z*14B205*NA Module Asy - ECU), and reset the windshield.

Apparently the water didn't damage the GEM, the failed relay did. When the relay failed, it sent a spike to the GEM and fried Pin # 16. Here is what was written at the bottom of the service sheet:

Tested with WDS check for on demand codes passed. Continuous memory found code P1812 four wheel drive mode solenoid circuit short to ground/P1 820 transmission transfer case low to high shift relay coil circuit failure. Replaced shift motor. Monitor PIDS, Relay/motor works but not by command from GEM. Diassembled Dash. and check 4x4 relay replaced. Motor now turns. Performed further diag. Pin #16 of GEM module (Circuit 78 1) Cannot create ground test wiring okay. Replaced GEM. REtested verified repair reassemled dash.

$600 was labor, $100 to have windshield fixed, the balance was parts/programming GEM.

There you have it, my experience in a nutshell. Good luck to anyone else with this problem!

Joe

 

I know this is an old thread, but I found it while searching about my problem. I am having the same electrical problems that everyone else here has had. Was there ever any information from Ford about a recall for this issue? If I can find and repair the leak, how possible is it to replace the GEM, Relay, and Fuse Panel myself? How probable is it that it is the GEM module and not a corroded fuse panel? Or is it both? HELP!

 

Okay...I haven't found or fixed the leak and haven't fixed the electrical problem yet. Well...we had a hard rain again yesterday. Blower keeps blowing, wipers and windows sometimes work, sometimes don't, no radio. In the past, when this happens, everything is okay after the rain stops and the truck dries out. If I leave the blower fan on the battery dies. Well, last night I was very careful to turn everything off. This morning...dead battery and clicking under the dash! Took the wife's truck to work. Came home, jumped it. Started right up. Turned it off and on a few times..good. Turned it off, went in and when I went back out an hour and a half later...battery is dead again and the clicking is back!!!!!! Could it be that the cold weather has kept the truck from drying out and whatever is causing the constant clicking is draining the battery??? Please help, my wife and I need both vehicles tomorrow for Thanksgiving. What are the chances that if I jump it tomorrow and get to where I'm going it will dry out if left in direct sunlight??

 

i think the problem is the make of the vehicle i have had a 1998 ford for 10 months and all these so called little problems keep popping up one after another haven't found one yet that is a cheap fix yet i love the truck but i can't keep paying for these problems that the manufactuer should be going good for they just ignore it well need less to say this will be my last ford and i would advise anyone else not to buy this junk!!!!!!!!!!!!!!!!

 

Hi Ya All. Mine Was Doing The Same Thing Took It In To Ford 1000.00
*%$###$# Dollars. They Told Me It Is A Rare Problem, I Flipped Out On The Service Guy. He Is Going To Sharpen His Pencil And Come Up With A Lower Number. I Purchased The Truck From Them 99 F-150 Ext Cab 4x4 5.4. Other Then This Problem It Is A Good Truck Drives Like Its Brand New.

 

every problem they have is a rare one it just seems that alot of us here are posting the same problems i just had my windshield repaired this week it cost me 165.00 everything is working fine for now i hope it stays that way and i saved it before the damage occured only problem is the air bag light keeps flashing going to dealer monday to get exhaust manifolds fixed for the third time thank god i don't haveto pay for that good luck!!!!!!!!!

 

I just found this sight and wanted to weigh in with my Ford experiences. I have not had the water leak and electrical probelms I read about, but have had enough others to last a life time. The best one I had was a 75 Ford truck my folks bought me when I turned 16. All the others since (there have been 9, all new) have been a POS. I bought a new 79 F150 when I was a senoir in HS, got 1/2 mile from the dealership, the engine died and would not start. I walked back to the store and tossed the keys on the salesmans desk and told him he needed a tow truck. Turns out it was out of gas, but the guage said it had 1/4 tank left. That was the first of many problems, one which it was in the shop for 2 weeks at one point.

The 2 worst problems were the 92F150 that burned down in the parking lot at my work. It had a short in the wiring harness to the alternator, which caught fire. There was a recall for that problem, but FORD told me that my serial number was not listed as one affected by the recall. Insurance paid my claim and raised my rate.

The other was the 97 F150 I bought to replace the one that burned. It was about 18 mos. old when I got a letter from Ford telling me there were defective lug nuts and they may come loose without warning causing an accident. Further more, the replacement part would not be availale for 4 months, so I should check the lugs regulary to see that they are tight. (Keep in mind lug nuts have been around for decades, why are they defective now?)
Sure enough, before the new ones were available, mine came off at 70 MPH and I crashed. Ford denied all responsibility citing the fact new tires were installed 4 days / 800 miles before the accident, and the tire shop was at fault. I dont see how I could have driven 800 miles with loose lug nuts. Once again insurance paid the bill and cancelled me. Three attorneys told me I had no grounds to sue because I was not injured in the accident. About 3 years later, the rear end dissassembled itsself on the highway. The right axle came out of the housing (with wheel attached) and flew across a 4 lane divided highway in the dark and landed about 2 blocks from where it came out. Its fortunate it didnt go thru someones winshield and kill them. It was long out of warranty so I did not even bother to get help from Ford. So I bought a new..... FORD! Am I stupid or what? I have an 05 f150 that I just hate, soon to be sold. I may have gone from the frying pan to the fire, but I have replaced it with a Chevy 1500. Time will tell. SO I too am through with FORD trucks.

 

its been a couple of months but i'll chime in. My 2002 has 93,000 miles on. so far i've put a cylinder head on it from a spark plug blow out. i now need new u joints, a lower ball joint, my rear limited slip is shot at $600 for the replacement and now the leaking windshield and electrical problem that is going to cost me another $600 or more. I have had this truck for a little over two years and bought it with 60,000 miles on it. I have never put sooooo much money in any vehicle i have owned in the past in such short time. this truck is five years old!!! fairly new to my standards!!! POS...I too will never buy a ford again. I had a '89 toyota p/u with 220,000 miles on it and put no money into before i sold it. my next truck will be a tundra!! goodbye FORD

 

i work i servce at a ford dealer and have seen this alot...normally it is the windshield leaking and the water runs down the fire wall and gets int the fuse panel/gem module...if you need a gem you will also need a fuse panel. i would definately get the windshield leak fixed first because while they are fixing that they may be able to check the body seam that is there...i have only seen one body seem leak and at least 20 windshield leaks and all needed fuse panels and gems...

 

mine is going in next week to get everything replaced...windshield, fuse panel and gem. My windshield has a leak at the top on the drivers side. its been there a while but was never a major leak. I've now lost my four wheel drive so we'll see.......all the other little quirks have stopped so idk!! dealer told me $600 but idk if the 4wd will change that as some on here have had to replace relays!! :santa:

 

one good word for my ford truck>>> I just plowed 2,000 sq ft of 6" of snow in 2wd!!