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I have used vinegar and salt on many rust remmoval projects around my bike shop. It is amazing how well it works. Just gotta make sure to neutralize that acid afterward with baking soda water... I am particularly impressed at how well you've managed to do on this GEM unit so far. Good job!
Got it back together.
No more crazy relays clicking.
Or random heater turning on.
or key in ignition alert without a key.
removed the wiper arms and plastic cowling
tried pouring water over windshield.
But could not find a leak.
will try more tommorow with full garden hose.
would like to not have crazy wipers and windows ect when it rains. There is some mess of silicone i found under the cowling.
Windshield is junk but appears well glued. There's plenty of primer. Hopefully I can find and correct the leak.
solve.a problem someone before me obviously was dealing with.
Got it back together.
No more crazy relays clicking.
Or random heater turning on.
or key in ignition alert without a key.
removed the wiper arms and plastic cowling
tried pouring water over windshield.
But could not find a leak.
will try more tommorow with full garden hose.
would like to not have crazy wipers and windows ect when it rains. There is some mess of silicone i found under the cowling.
Windshield is junk but appears well glued. There's plenty of primer. Hopefully I can find and correct the leak.
solve.a problem someone before me obviously was dealing with.
From what I've gathered around the forums and from a guy answering me on another post, the famous trouble spot seems to be the top edge of the windshield and the associated trim pieces.
I just wanted to take a second and let you know what a good job you've done on your truck, as well as what great documentation you've generated on here! Excellent work!
You've inspired me to tackle this with my truck, as I'm not to a failure point yet, but when it does act up, I want to be ready with a rebuilt unit to put in right away. I had a pretty good scare with my recent 4x4 system problems...
Thank you for following along this mess of a thread ive.made.
Best wishes with your gem/fusebox.
wish I knew years ago all the issues it can cause.
was.stumped. for a while on 4x4. Electronic shift
2 shift motors and a.transfer case later.
Just a little corrosion in the gem
shame it's usually replacing windshield, fusebox, and gem.
Hopefully I can locate my leak before water causes it's havoc again.
Fingers crossed no more dead battery. Bucking/stalling.
and maybe my speedometer will stop bugging out.
to be determined..
Guess i got kinda what I wanted.
Happens To be raining.
Was a near constant drip off fusebox last time in this light rain. 4am in land of the midnight sun 🌞.
Last edited by Stillconfused; Jun 11, 2025 at 07:09 AM.
Fresh Update. Had to use garden hose but finally saw a 💧 at bottom of the pillar trim.
windshield appears to leak at top. Some of corner and about 8 inches toward center.
Not affording a windshield so I 🤷 did what I could do.
pulled the windshield side molding and near half the upper trim.
Cleaned out the grooves. And unfortunately only had some kinda extreme gorilla construction adhesive..
It laughed at my cheapo caulking gun
so as necessity dictates i got creative.
Used my ball joint press.
never made such questionable repairs.
but if it works and gets me to work without cutting out.
it may get a new windshield for Christmas 😀 Ball joint press caulking gun.
