I am now having this same problem. Has anyone had the luck of fixing the leak and everything drying out and working normal again?

 

I am having this same problem as well. Just happened to find this site while look for a solution to my problems.

 

I can't believe it was so easy to find all you guys with the same problem I am having. We haven't gotten any significant rain here in South Texas till this weekend. My truck has 132k on it and has been great until Saturday morning. I had the trailer and 4 wheeler hooked up and ready to go play. Battery was dead. Jumped it off and started rest of the day. Dead this morning again. Found slight bit of water on the driver's mat and something is clicking up under the dash on driver's side. Fuse panel doesn't seem wet. If I get the leak fixed, will everything dry out and function properly? Will I have to have whatever's clicking replaced? My key remote also does not lock/unlock the doors right now. Thanks for any help.

 

Well, I changed the oil & filter this afternoon. Started the truck and let it run for awhile. Shut it off and now it cranks but won't start. I'm thinking that the antitheft mechanism has shut the ignition down now. I'm pissed. Now, unless it happens to start in the morning, I can't even drive it to the dealership to take my beating. Newer vehicles are nice, but I almost would like to go back to the old days without computers and EFI.

 

One glass shop tested the windshield and said it was sealed. I talked to another glass shop and that guy new exactly what I was talking about and said if I still had the factory glass, it was a defect from the factory. He pushed out on the upper driver's corner of the glass and told me to have a look. The windshield definitely moved outward. Today they pulled the glass and resealed it. The guy said that the glass would have popped right out if I was in a wreck because it was basically only sealed on the bottom and some of the sides. My GEM dried out and functions properly and hopefully my water leak is fixed. I consider myself lucky to have found it in time. Only cost me $100 to reseal the windshield. Hope this helps someone.

 

does anyone know whether the 97 expi gem is programmed or pre programmed??? I pulled mine today and no signs of corrosion in either fuse box or gem, should I go to the dealer to have the truck scanned?, my 4x4 wont work and I dont hear the relays click when I start the truck like they used to.... can this discern b/w a bad transfer case motor or bad gem?

 

I have the same problem with my truck, 99 F150. The problem has been there for several years and happens only during severe rain. I have been told the problem is not in the windshield seal but in the seal on the hood that seals to the front of the wiper cowl. If you open your hood, you will see the seal runs short by about 6-8 inches from the corner of the hood. This is where the water runs down into wiring on both sides of the truck. On the passenger side, there is the plug into the computer and on the driver side there is a large wiring harness running to the main fuse box. When it rains, both sides get soaked. I don't know which side causes all the electrical problems. I have been told that by putting in a weather strip on the area left unsealed, the flow of water would be diverted to run behind the fenders. You can see where that appears to be the intention of the factory design. I have not tried this yet, but I did duct tape the wiper cowl completely on the second day of four days of rain. By the third day, the harnesses had dried and the problem went away. So far, I have been unable to find a seal large enough in diameter to seal the gap. I have not tried looking at automotive seals yet. I would like for any of you to look at the seals yourself and get your opinions on whether you think this might solve the problem. I know some people get water inside their cab and that would be a window seal but I don't get water inside and the windshield is tight on my truck.

 

I am having the same issues and just found this site. Good to know I'm not the only one having this issue. I too have a 97 F150 and am on my second GEM module and fuse box in 6 months. Last fall the dealership told me it was water that ruined the fuse box and GEM module. My truck died on the highway. They couldn't find a water leak and so I stupidly let them replace the module and box and it cost me some serious coin. Six months later the truck won't start again, dead battery. I jump it, charge it and then when I shut it off, the headlights won't go off and kill the battery. When I take it back, they tell me the module and fuse box are shot again due to water leak. AFter much threatning and arguing, they finally agree to replace the module and fuse box if I replaced the windshield which I have and am now waiting for the truck to be done. The windshield guy said he didn't see signs of any leaking. I'm going to try looking at the seams as noted by ClintC.

 

I had the same problem everything went funny the speedo,fan, light etc. It was actually a leak around the windsheild (Recently installed ) water coming in and shot out the fuse box had the windshield taken out and reinstalled fixed the problem after replacing the fusebox , was full of water when I took it out.

 

Im afraid to tell you, but since you know now anyway there had been a TSB out on this for the last 9 years. That problem is almost endemic to that series of truck.
I was going to post a detailed resolution with pictures, but I lost most of my written documentation. Let me see if I can give you a heads up to mitigate most of the problem; before you go nuts.

Look' first and foremost not only is there water leaking around the frame of your windshield, but that that there is a ledge directly above the GEM that is probably full of water too. There is a vapor/condensation shelf that collects most of the moisture and water that bleeds down around the windshield, and passes it out of the cabin via bleed holes. When it gets full ;it bleeds out right above the GEM/Fuse Panel and gets into IC Electronic circuitry which causes the most problems.

However I would not replace the GEM under most situations. What I would do is to immediately make a plastic of fiber-glass "bonnet" to cover the back if the GEM Fuse Relay Panel. It is the only way to help in this situation until you correct the leakage at the windshield (which is a task in itself). Imagine a shower bonnet placed directly over the back of the IP Panel shielding it from dripping water. That is essentially what I am talking about. The issue with the GEM (directly above the relay/fuse panel can be resolved with a mild solution of Electrical Contact Cleaner, and a hair dryer. Most of the time the water has inundated the GEM's circuit board which contains several integrated circuits chips. The board has become contaminated, and will fail several circuits simultaneously. What is needed in that instance is to wash that board with circuit cleaner thereby removing both the water and contamination. It's not easy getting direct access to the board, and so you need to rely on flooding the board through a vent hole, and allowing the board to dry thoroughly. I have done this many times to several friends trucks, and it usually works. Washing the truck, and heavy rainstorms usually exacerbate the problem; which can usually last for weeks until the dripping from that shelf subsides.

 

Need help. GEM replace 3 years ago, and now happening again (rains and windows and wipper won't work. Dried out GEM and work fine for a few day. THen it rain and then without being in the vehicle it tried to start by itself. Disconnected battery and removed fuse box and GEM and clean thoroughly. Put it back an not it won't start.

 

Sorry Vehicle is a 1997 Ford F150