'01 Expy XLT, 4wd, 5.4L Triton, 4R100 trans, ~171K miles
Heater core failed last spring, also decided to replace blend door while in there. BTW, what a pain in the a** to access! Big heavy dash, dropped the column, completed the fix with the help of my wonderful (and tolerant) wife.
(I just hate doing something for the first time, being frustrated, and have a calm and patient person on the other side of the rig giving me positive looks and encouragement. I want to be mad, dammit!)

Now for the electrical gremlin: About a month ago started having intermittent electrical issues. First started randomly lowering and raising front windows, never fully. Felt like the rig was haunted! Then electrical door locks weren't functioning all of the time, randomly locking and unlocking while running. Dash lights and warnings would come on and off, particularly at startup. Then the transfer case would randomly engage to 4HI randomly, particularly when in a parking lot or pulling into/out of driveway, even occasionally briefly into 4Lo when making slow speed maneuvers in a parking lot. Finally got so bad the gremlin began being consistent.

Been looking at all of the connectors under the dash and under the console, even pulling the console out once again. All checked out ok. Physically pulled and jostled the wires under the dash to try to replicate the issue to no avail. Double checked all of the ground connections to make sure they were tight, all ok. Finally, out of desperation, decided to disconnect each and every connector under the dash, clean contacts, dielectric grease, reassemble. No love. Began to clean the grounds on passenger side first, near the kick panel. Lower ground point has two ground wires on one screw/bolt. Found some minor corrosion between the two flat contacts and cleaned them. Reattached body screw to panel, and Voila!, no more gremlins!!

I think the screw may not have been fully tight (felt tight when tugged, checked by hand) and allowed for an intermittent connection for the ground. Each wire has a flat blade about the size of a dime on their end and are doubled up on this ground point. Not having the screw tight allowed for corrosion to begin and progressively get worse. Now corrosion free and tight, no more gremlins.

I hope this can be of help to someone on here as I had scoured the FAQs and queried the search engine in the forum to find a similar problem without any luck.

 

Funny what ground wires can do... Glad you figured it out... Imagine driving on the highway and your 4low kicks on...

 

was it in the kick panel or in the dash? I mean can i reach it without pulling the dash or just pull the passenger kick panel? i have one i'm chasing right now...it's frustrating...lol

 

I found it in the passenger kick panel. No need to pull the dash again. Good luck. Electrical gremlins are a pain.

 

well I found mine it's definitely the gem module thanks for the reply. I see a lot of different numbers on some of these gems on eBay and they all say they work on a 97 Expedition I really sure which one to get

 

Match the numbers up. Your seller should provide pictures, and you should be able to read the numbers. When I replaced mine, I typed the number into the search bar and let eBay find it for me. $100

The numbers are on a White Sticker on the GEM Module

 

did you have to reprogram it? i've been reading some say you have to take it to the dealer, and some say it will program itself when you put it in?

 

No, that is what the number matching is all about. The difference is what the truck is equipped for. If your truck doesn't have power windows, a GEM module from a truck with Power Windows won't work. The module has to match your equipment. A module for a 4X2 wont work in a 4X4, etc.

Match the numbers up.

 

okay gotcha thanks

 

holy **** that's a pain in the ***, i got it loose enough to see the numbers now, can't figure out the bolts on the back to pull it out...taking a beer/meditation break. y'all aren't gonna believe this...apparently it's had issues before i bought it...there was enough paper towel and plastic bubble wrapped crammed behind it in the dash so i could barely move it at all....oh and a lid off a deli tray (sharp *** plastic) SMFH....LOL water came pouring out when i pulled the "stuffing" out from behind it...

 

OK, before you buy a new one. Your windshield seal is leaking. You'll need to get it resealed (windshield shop). Shouldn't cost much and they'll come to you. YOU CAN NOT RESEAL IT. Let a pro do it. Call around and get a good price.

Pull the fuse box to make it easier. Once you get the GEM out, put it in a ziplock with a bag of rice for a couple of days. Let it dry out. The rice will draw any moisture from it.

If it's bad though (I'd bet it's not) you'll have to pull it and swap it out again and that's a pain.

It still works, so it's probably still good.

 

oh definitely, I'm actually gonna over kill it...got a buddy that has a glass shop, 100 bucks new windshield and seal it all up the right way...lol. I was just amazed at how much water ran down my arm when i pulled the plastic bubble wrap out from behind it. I was thinking too...that spray flex-seal stuff...it's just rubber right? was thinking of coating the back of the fuse block and gem with it before i reinstall, and of course a nice thick coat of dielectric grease on the big plugs with bolts. think it would hurt anything to put that flex seal on it?

 

I've never used Flex-Seal on anything, but I know people who have and they've all been satisfied.... I wonder how it would do as a rubberized bed liner........

It probably wouldn't hurt to seal everything up...but the windshield has to be sealed. Flex-Seal might prevent the GEM Module from cooling properly, but I doubt it....

I have to go buy some of that stuff and try my bedliner idea...... if that doesn't work out, I guess I can build a mold and make myself a new girlfriend....