First off let me introduce myself. My name is Jim, I was on this site three or four years ago and ya'll helped out a lot. Hoping you can again
The truck: '02 F350 SWR 7.3L 4x4 Crew Cab Lariat w/ just over 290k miles

Now the problem: Recently i've been having some electrical issues in the cab of the truck. Symptoms: Radio shuts off completely (no power whatsoever-not even the clock). When this happens, the dome lights (not the big one but the two on the outside of the large one with the overhead switches) will not turn on either, and the power windows also stop working. It happens randomly, and everything will stay "powerless" from anywhere to a couple of seconds to a couple of hours. Shutting the truck off and cycling the key doesn't help, as nothing really does. I've basically just been stuck waiting for the power to come back. Its not really a big issue, but definitely frustrating...especially when the windows get stuck down and it starts raining. I've checked the wiring behind the stereo, both passenger and driver side switch panels, fuses, and i'm now at a loss for the most part. I'm gonna check the wiring in the rubber conduit in the door jams next but after that i have no clue. Has anyone else had this problem and has the possible solution, or is there anybody that has some other ideas to what could be wrong?

 

sounds like the GEM under the dash is getting wet maybe from a leaking windshield.

 

I had a problem with my radio and it ended up to be inside the drivers door. The wire bundle going into the door broke it's holding tie wrap and the door plunger was hitting the wire bundle and wearing the wires. It's easy to get door cover off to check.

Good luck!

 

I think snakedoc is on the right track. I don't have a wiring diagram for 2002 (mine is 99) but the only thing that the power windows and interior lights have in common is the GEM. The accessory delay relay (which supplies power to the windows) and interior lamp relay are both controlled by the GEM, which can do strange things if it gets wet due to a windshield leak.

 

Mine does the very same thing and has for years. when it happins, tap the top of the dash on the left side of the radio. I wish I knew the fix because it is annoying.... 02 does not have a GEM it has a VSM mounted on the firewall behind the radio....

 

Thanks for the correction, I knew there were some changes from 99-02 but I wasn't sure exactly what they were. OP: don't spend any time looking for the GEM

 

I have the same thing in my 02 Mason dump (7.3) and a friend of mine just bought an 02 F250 with a 5.4 gasser in it that does the same thing. I haven't dove in yet, but I'll be following your progress here now.

 

Lol glad to see its a common problem at least. :-) I could be wrong here but I'm pretty sure some of the 02's do have a GEM module, located behind the glove box. I had it out at one point when trying to fix a problem with the 4x4 SOF. Ended up not being the issue but I could pull it out again and look for signs of water damage. But like I said could be wrong, could be something else. 😜

 

Are your batteries both in good shape with clean connections and no corrosion visible where the wire strands are compressed? Are your grounds, especially inside the cab rust free? Star washers between the terminals and cab steel with a little grease will ensure no moisture or corrosion. 12 volt power problems sometimes cause symptoms that make no sense. Is the main cab ground clean? Try running a temporary ground cable at least #12 or #10 from one of the batteries to the cab. Measure voltage between battery post and inside the cab. There should be very little voltage drop.

I had one of my batteries go bad and it caused very similar problems. The battery actually tested ok, but the batteries were old, so I replaced them anyway. Wierd problems went away.

 

Mine does the same thing sometimes. I just open the door and slam it, and all is OK.

I am going with WhiteyFord.

 

GEM module is located behind the fuse box above the e-brake pedal.. VSM is on the firewall behind radio/glove box, in that area anyway..

 

Reading up on some other forums, I've discovered this is a really common problem. Almost overly common, especially with no definite fix. If anyone else is having the same problem, I've read that there is a "battery saver relay" inside of the instrument cluster control module which keeps your windows and radio going after you turn off the vehicle. This relay supplies power to the central Junction Box and to the Accessory Delay Relay which you can apparently jump with some wire and it will work. I'm not sure if this will work but i'm gonna give it a shot tonight and i'll let ya'll know.

 

Check out this forum over here as well: lots of possible problems/fixes what not

Radio and windows stopped working... - Ford Powerstroke Diesel Forum

 

So solution half *** found as mentioned before. Measured voltage on fuse #41 and wasn't getting a reading at all, checked the accessory relay (#306). Relay checked out and is working properly, so I measured the voltage in the bottom slot, measured 12.84V. Tried jumping the relay using bailing wire, and bam! Everything working. Leads me to believe its the ICM. So I used an alligator clamp and jumped onto an ignition wire to bypass the relay. now everytime I turn on the key everything works, key off nothing works...not necessarily the right way to fix it but definitely works and definitely cheaper!!

 

The hybrid instrument cluster was introduced in 2002 (I believe) and you are correct that the accessory delay is located in the cluster. The cluster is directly linked with the VSM, they work together. When I was having issues it turned out to be the VSM, which was good because the cluster is non serviceable and costs $1,100 plus programming.