I have an f150 (2003), the AC fan just started to come on and go off randomly yesterday with no keys in the ignition. There is a clicking sound coming from under the air filter that sounds like a relay pulling in and out causing this problem. Can someone provide me with more information about this problem? I'd like to fix it soon if I can. Thanks!

 

I suspect that you've got a windshield leak, maybe so small that you don't notice. If you look under the dash near the fuse panel, you may find trails or other evidence of water. The water gets into the fuse panel and GEM module and causes really weird stuff to happen. You'll probably find the dreaded green death in either the fuse panel, GEM or both, so they would need to be replaced also.

 

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Dubs, what did your Ford dealer do for you? My '02 F150 is currently at Balise Ford of Wilbraham for the exact same thing you wrote about. I'm told I need a new GEM Module, fuse box, and windshield. Is this something Ford should take care of, even though the warranty is out?

 

I called Ford directly, spoke with a customer care person. Explained the situation in detail, and she advised me that they will be in touch with my dealer. I then called the service manager and discussed the issue with them. Ford is making an "out of warranty adjustment" and covering the repair job 80%. Seems Ford is aware of a leaky windshield problem with the F150, Expedition and Excursion.

Hopefully more people will call Ford and their service manager and Ford will do something official.

 

You guys have been a huge help! Jroyce, I have not been to my dealership with this problem yet, it has only happened one time but you never know when it will happen again. I'll get in touch with my dealership and see what I can get done. I think I'll use these posts as ammunition. Nothing comes easy when dealing with auto dealerships. If you get anymore information that might help me, please post and I will do the same for you. Maybe we can get them to take care of this mess and cover the job 100%. Who knows, I guess we'll find out.