Again, all of the information you seek is in the factory manuals. A Haynes manual is a joke for this type of work. The factory manual is 3 inches thick and the wiring manual is another inch thick. Yes, they show where all of the parts are. Yes, they tell you what they do. Yes, they show how they are connected. Yes, they tell you how to diagnose them. All of the answers are in there, that's what they're for. I use these manuals 50+ hours a week as do several others here.

As for the GEM, as its name implies it is a generic module common to many vehicles. However, the software it is programmed with is unique to each vehicle line and its options. Your friend at the dealership can cross reference the numbers off of the one you have and let you know what numbers can be substituted.

 

The Ford manuals of today are much thinner compared to manuals in the past because they tell you less. Some assemblies aren't servicable and are just replaced. One example is the rearend on a 4WD, other than seals is just replaced.

Explaination of 4WD operation is vague at best. Questions I asked my dealer about 4WD operation couldn't be answered and even when they ask their Tech Support, the information wasn't available.

The manuals "clearly" mention intermittent problems and problems that produce no DTC's' yet try to get a dealer to look into a problem with no DTC and that they didn't see on their test drive.

 

If you want to poke around here: Buy 2002 Ford Escape Parts | FordParts.com

You can select 'electrical, lighting and body' and sub-select 'control modules' and the GEM will show up and you can click on the 'view image' link and you may find the picture you want to see. Or select another component, and view its images, and you may get to see the dash layout. The Gem costs $ouch. ~$320 ... I'd be trying boneyards, or 'pick-a-part' type sites.
tom

 

The '02 Escape electrical diagram book from Ford doesn't have a diagram showing the GEM by itself, only similiar to what I posted above.

 

My experience is the exact opposite. The manuals are as large as ever, and the newer Escape manuals are even two-volume sets. They have been reformatted several times over the past decade or so, and the latest ones are the best by far, IMHO.

Not sure what the problem was with the 4wd, but between the shop manuals and new model training, our techs have no problems understanding and repairing the systems. I just read through the manual for your vehicle and think I have a pretty good understanding of how the system works (I don't normally work on drivelines.)

As for DTCs, the vast majority of vehicles I work on have no codes to accompany the owner's concern. I find the new manuals to be very thorough and well-designed, in contrast to what we had in the 1980's and '90's. Almost without fail they will lead you directly to the cause of the symptom in a very efficient manner.

It seems to me you are in need of a better dealership if they can't answer your inquiries as a consumer.

 

For instance, starting with the '07 PC/ED manual, they left out all the PID memory locations. Was this so nobody could program certain types of OBD-II scanners?

The older manuals would provide resistance charts for certain sensors, not any more. What do when a EPSA motor or module goes bad? You replace the whole steer colomn assembly.

The manual shows certain function tests for 4WD operation like a locked full turn on dry pavement at <5MPH should show >20% rearwheel torque. How much rearwheel torque driving straight at low, moderate or heavy throttle? That's what not even your Tech Hotline could provide an answer for.

How come the problems with the 6F35 transaxle that surfaced in '09 when it was first introduced are still happening in the '11MY? Yet, they still rant/rave about Ford's improved quality!!!!

I almost got T-boned when my Escape hesitated badly making a left-hand turn. They said, no DTC and it passed their test drive! Later I was able to reproduce the problem and "only" then the Tech Hotline suggested a PCM reflash which fixed the problem. Why not just do the 20 minute reflash to attempt to solve the problem on the first visit??

BTW: My VIN entry of the hesitation which never changed to show that the issue was solved nor did I ever receive any paperwork either.

 

Probably because their research indicated nobody used the info. Can't say I ever have, so why put it in there?

Which is the exact reason why you don't need values for parts you can't service. As for charts, they are still there, generally incorporated into the pinpoint test if necessary.

Don't know on that one, or why you would need the info. The tech hotline is usually more hassle than it is worth. You usually need to call about three times before you get an experienced person to answer the question. Before that, you are just handed canned answers from the database.

About the only problems we see right now on those are from people that never came in for the reprogram and are now reaping the benefits of neglect...

Because in Ford's world, if you can't explicitly state the reason for replacement of a part, then it is an unnecessary repair and Ford doesn't pay. We can't test software, so unless there is a TSB to reprogram the module, Ford says no way. How am I, as a tech, supposed to prove to Ford their software is bad? I do "free" reprograms every week for people and can't get paid a dime. Just did one today on a Flex as a matter of fact. You mentioned that the repair did not show up on OASIS. That is because the claim was never submitted by the dealership, or was rejected by Ford. Either way, the tech that worked on your vehicle probably got paid nothing for the time he spent working on it.

 

Hey Guys - I took the cover off the GEM box (at my bench with a static wrist strap), and it turned out to be a waste of time because the board is very corroded and burnt in spots. My friend at the dealer quoted me $280 for a new box but I can get one from the boneyard for $70. What I am unsure of is why it would have to be taken to the dealer for programming when it was removed from the exact same vehicle. These are EPROM type boards so it would be like updating the bios on a computer motherboard. I can see that the factory remote "ID" you would maybe have to change but as long as you can program another remote what else would need programming in this box? The lights, windows, and doors are the same on all Escape 3.0 trucks made in 02. I don't think the passive security goes anywhere near this because this box is cooked but the truck still starts. So what would HAVE to be programmed at dealer? We recently put Trans in 03 Neon that also supposedly would have to go to dealer for programming and it worked just fine as is. Still working fine everyday for my brother's wife.

As for the manual issue - I mentioned a little about my situation and I know it is not your concern but I am a US FED that was hurt in the line of duty in a bad helicopter "incident" (their term) and have had 38 MAJOR back, hip, & foot surgeries since 91. I built a big shop with lift, paint room etc. and restore cars and motorcycles for something to keep me busy and keep sane. I let my brother use the shop to do work so he can make a little money for his family and in return I make him do my heavy work that kills me. In the last two weeks we did a clutch, springs & struts, and window regulator on a 03 Civic. Motor swap, clutch, and struts on a 01 Camry. Motor, and front suspension on a KIA. The first two were for people at my wife's Law Firm and the KIA is for us to sell. I can not buy real manuals for all of the machines we work on.

Being on disability my income is limited and I can only go a few hours at a time. My Genisys machine usually gives me a good idea of what is wrong with vehicles and even though the electrical codes I got from the Esacape DO NOT turn on a failure light I was able to find the codes - I just do not know the physical location of the actual parts (like the power door lock relay coil). If I am going to keep this for my child for years to come I may think of spending the money on the full set of manuals - but I have 7 vehicles registered in my name so buying full manuals for each would be pretty expensive. I bought my 5.0 Explorer Limited new and do not even have the full manuals for it. If you guys have them via work it is easy to give me a hard time about not having them when you do not have partial income and a fleet of vehicles for family like I do. I wish I could buy them all but I can't so if that is irratating to you guys I am sorry.

My friend at the dealer is the one that said he thinks most of the actual relays are on the back of the fuse box and I took his word for it. He is a parts guy not a tech so I can not blame him but you would think his diagrams would show locations. Anyway - I am going to buy the used box from the same year truck, same numbers on box as described by my parts friend but I was hoping one of you would tell me what exactly does the dealer need to see it for? If just to program the factory "master" remote frequency then I would think as long as I get a second remote to work why spend the few hundred they would charge to "program" the box? I appreciate all your help and again I am sorry I have limited income now so I can not just go buy factory manuals.

 

There's nothing wrong about asking about the so-called On Demand 4WD System that really isn't works. Intelligent 4WD, it isn't. Some people still believe that it "only" kicks in when wheel slippage occurs.

You must work for a low volume dealer. You've never seen a left-hand half shaft leak? So many that Ford created a repair kit which has been national back order several times. This is one that started in '09 still occurs in '11MY.

My PCM has been reflashed three times including the recall, once after the recall.

The original visit on the hesitation was entered into OASIS where they did nothing was. After I complained to Ford CS, was able to reproduce the problem. They called me to setup a appointment for a reflash, that wasn't entered. Not sure if a old entry can be changed/edited/deleted or not

 

five-Oh!, I think the keyless entry and anti-theft & PATS were not part of the GEM back when. I would do what you propose, and hie thee to a boneyard. I can see $70, but 300 is a little steep. It might even be possible to bypass the GEM stuff and get power to the other systems with some modest rewiring.
In passing, I would suggest that you check your local public library for access to auto repair manuals. Ours here has a system you can access on-line once you enter your library account number. It doesn't have the latest manuals, but it might have more of what you need at little expense.
I was able to access it and get wiring diagrams for my little sister's Odyssey when her A/C fan went toes up. It also allowed me to rebut the 'repair' person who suggested she ground the A/C clutch with a jumper wire because 'the control head was not producing ground to enable the clutch'. He even offered to put a switch in her glovebox for an extra $30 so she could have either Max A/C or nothing. Didn't even look at the fan speed control that I suggested from 500 miles away. It only had Hi fan or nothing. Duh. Resistor pack, but Honda used a pwm circuit to diddle with the voltage/amperage and make the fan blow at the speed the control head wanted. He didn't diagnose the problem, he diagnosed the symptom, no A/C. A failsafe to protect the system. Duh again.
tom

 

One of the many things I was trained for by our tax dollars was to speed read. Because most of our contracts and documents are so big and full of BS and double talk. When I am too sore to work I read - the ladies at our library all know me by first name because I read a book a day (every day) and I never thought of the library for info. What did you look at in the library? I know there are paid services on the internet like all data and others but does your library have access to actual repair info like Ford manuals?

I usually do not work on other peoples cars - just ones to fix up and sell or my own - but my relatives and my wife are always getting me to do other peoples machines also. My brother takes what ever he can get because he needs money bad. I have put brakes on for someone that was told by their "guy who is a friend of the family and we have used for years" that told them they needed new calipers and tone rings etc. etc. because the wheel shook under braking. They needed $30 rotors and $45 brake pads. I worked at Ford, Toyota, Pontiac, Buick, Caddy, VW/Porsche, and Chevy dealers before going to work for US and getting degrees in Engineering and Business so I am always amazed at what places do to people that do not know cars.

Right now the car market for used vehicles in our area is so bad (decent used cars are scarce) that when my brother in law (High school teacher) had a noise in his Honda a place told him that his engine and trans had both "gotten to old" and needed to be replaced but they would give him $2500 for his 05 Honda. I told him to bring it over and when we took a ride I asked him where he heard the noise (Front or Rear) and he said the rear. I asked him which end the motor and trans are located and he agreed in the front. I showed him how there is no noise in the motor at idle. It was just rear hub bearings rumbling but it shows what lengths "shops" will go to.

So I agree with you that some shops are really clueless, some are lazy, and some are total thieves. Let me know how you looked at repair info. Would be great to find a larger library that actually subscribed to one of the Tech Services data systems. My little town has a library (the ladies joke that I have read every book in it) but our card can be used at just about all in the state.

 

I am in Cherokee County, GA. The library is a county wide org.
This is the URL for their source provider:
Gale Cengage Product Failure
They want your library card #, and know from the link where you came from.

This link was my 'cheat' because I know where it will end up:
EBSCOhost - world

Again, asking for your library card #, and it lets you browse. Inside was a link to "Auto Repair Reference Center" which took me to:
EBSCOhost

That page had vehicle year choice. I clicked on through to Make, Model, sub-model, and picked wiring diagrams [vs repair procedures], then picked power windows and then had a choice of 2.0l or 3.0l system. I picked 3.0l and got a PDF file. Opened the PDF, and had a diagram of the wires and switches and motors for the power windows, along with the fact that all power comes through the Delay Relay... FWIW.
So, if I were doing the surfing, I'd go to the large city library sites on line, and see if they had links to reference materials from an outside source, such as EBSCO.
tom

 

IT WORKED - IT WORKED - OH MAN IT WORKED. I put in the used GEM PCU box and used my Genisys machine to access the different areas showing failed access and cleared them all out and it all came back to life. I even was able to program the remote so I now have - door Ajar, interior lights, windows, door locks, and everything else back. The truck only has 70k on it so it really is in amazing shape and once I paint a few scratches on side and do my usual over the top detail work on it it will be as good as new.

I am going to talk to my library and see if they have something like what your library shows. I don't think my account in Connecticut will work in the Georgia system but they must have something similar in my area. That is really pretty nice that they do that in your area. Hope the system around me is as good.

 

What Genisys model are you using? I have a Solarity 4 channel scope, biggest hunk of junk that I've ever purchased. I had their OTC Perception and went to purchase a second one. After two wouldn't connect to my PC, I got the new, at that time Solarity which was a big mistake!

 

Good to hear it works. The GEM may be complex, but it is a lot simpler than what follows, from what I have read. Having two or three data buses running around in your car, with fallback rates in case of damaged components is unreal to me. I don't think the GEM will talk to the CAN bus or ...whatever the other one is, so may be you are lucky not to have a SJB.
BTW, five-oh I sent you a PM 4/27 re some PDF files ... perhaps for your records?
tom