I just had a weird thing happen to me... I hopped in my truck ('02 4.6L SCrew) and immediately heard a humming noise. I realized it was the heater, and sure enough, the **** was set to "Panel" and a low setting. I turned it off and, fearing the battery was dead, went to start the truck. All I got was an odd noise like fuses popping quickly and repeatedly as long as I held it in the start position. Anyone ever had this problem???? I need my truck back!

edit: also, even without the keys being in the ignition, it sounds like something is trying to turn on or something every couple of seconds or so.

 

Sounds like your battery is very weak. The popping sound is most likely the starter relay clicking. Charge the battery back up and have the alternator checked. If the Fan is on with the key off then that could be the GEM or a relay problem. Your post is not clear if the key is in the ON position or not.

JMC

 

sorry, when I first got in my truck I heard the heater (although the air coming out of the vents was obviously not hot at that point) running without ever putting the keys in the ignition. Having the heater running without the keys in the ignition was weird enough, so I figured it wasn't going to start. and sure enough... I also figured the battery was weak considering the last time I was in my truck was yesterday at this time and the heater fans must have been running ever since. But the fact that it was doing so without keys in the ignition and the odd noise every couple of seconds made me worry it was something worse.

 

Did you have a good snow, or nice rain right before this happened? If so I would bet money it's the GEM.

2002's are known for the leaky windshield that would allow moisture to get to the GEM.

 

as a matter of fact it rained last night and snowed this morning. the more I read posts about electrical problems the more i'm thinking the GEM got wet. what does it take to repair a leaky windshield?

 

I suspect the blower motor relay is sticking in the on position. I looked up the schematics and the relay has power all the time. The trigger circuit is hot only in the run position. Leave the selector switch in the off position and pull the fuse to the blower ( should be #24 ) to see if it stops the blower. If it doesn't the relay is stuck in the on position if is stops the switch is most likely the cause.

JMC

 

Alright, so I took the truck to a dealer. (It started up fine with a jump). They looked at it this morning and confirmed it was water damage to the fuse box and GEM module due to a leaky windshield seal. After searching these forums and the internet for a while, I see now this is a far too common problem among 97' - 03' trucks and expeditions... which, in my opinion is an absurd oversight on ford's part but anyway. The dealer wants 780 dollars for the fuse box and GEM alone, not including repairing the windshield. Instead I think i'll take it to a family friend and have him do the swap. I did a bit of searching on e-bay and found GEM modules for expeditions running around 100$ my question is: what part number GEM module does a 2002 4.6L 4x4 Supercrew need? I found one 1L24-14B205-BC for an expedition... will this work?

 

Don't know part numbers, sorry.

But I'm glad you found out the problem. The price for that is the same I was quoted here.

One thing you might consider is filing a claim against your car insurance. If you have the windshield coverage they very well may cover the crack in the seal, and any damage covered by said crack. It's worth a free phone call.

I would not tell them the amount of damage. Just ask them if your insurance covers the seal of the window from problems like air or water leaks.