Hello. New here. Been learning more than I will ​​​​​​remember on this website. Thank you 😊
Hoping to compile good information on gem modules for 97-03 maybe get enough together to make into a sticky.


ve a 97 f150 4.2 5 speed 4x4 msof.

belive my windshield is leaking onto both my gem module and the pcm.
gem been replaced once already. randomly hear clicking relays. In dash . Heater turning on draining battery.
my issue is when its wet. It will cut out while driving. Usually just like a few bucking . Couple times its like i turned ignition off for 3 seconds.
wondering if gem could do this?
ive gathered it can somehow cause a misfire.
But it totally cutting off. Makes me worry.
probably my ecm i think 🤔 oppinions?

Doesthe 97 up ecm have the issues like up to 96 did. With capacitors going bad? I dont find anything about 97 up repairs.

I probably answered myself. I think it's both gem and ecm getting water intrusion
if weather was better id be pulling both modules for inspection. So maybe this thread may continue in a productive way.

cheers.
Edit: ps ive owned at least 6 97-03 f series and expy
dealt with the gem making vehicle crazy or downright dangerous when wipers decide to quit ect.

id love some thoughts.
mostly wanted to introduce myself and invoke some responses.
Alaska here.
Drive a 97 f150. Have a 98 expedition. Brother has a 99 exp.
had a 97exp and another 99 exp. Every single one had gem. Issues.
causing random things from window random rolling down when using breaks. To vehicle decided to start cranking middle of night melted starter and cables so bad can't belive it didn't burn down.

 

This is my original gem from the 97 base f150.
burned a hole through the board. Dunno what issues it caused. Or how it burned 🔥. I bought it this way with a replaced gem that is also bad or getting wet.
next to follow is the replaced malfunctioning gem/fusebox inspection. And opening the ecm for a look.

 

My understanding has been that it's usually the fuse box circuit layers inside that short circuit, not the circuit board.

Also, most people fix the leaking windshield at the same time as fixing the fuse box. So it doesn't happen again.

Here's a good video on fixing the fuse box itself.

 

Ya kinda got ahead of me. But awesome 👌 video link.
I vote that should be a sticky.
hint hit the gear icon and speed video up
I was gonna compile knowledge and our experiences.

never seen a video like that. Actually opening the not supposed to be repair fusebox. I did it crash course.
myself. But was box from a 2000. To a 97. I had to swap quite a few of them metal tracers or whatever around.
I managed. To get it right. Actually don't think i changed gem on that 97 it was fuse panel issues

 

I had same issue on 99 expy with odometer looking like that one snake game from early 80s. I found that to be a bad solder joint in the instrument cluster.

My 98 expy starting going nuts. I put a gem from a the 2000 eddie Bauer in it. No problems. And they different options.
the 00 had climate control. Overhead console heated seats ect. Seems ive been able to swap gem that are from higher optioned vehicles to lower without problems
Im about to find out with my base 97 f150.
Its turning heater on randomly. Draining battery.
im a try a gem from a 90 esof expedition.
will let you know if it will still engage engage front diff.
Im guessing no becausebecaus 99 up don't have the actuator. But who knows
edit: 97 is manual shift 4x4 transfer case.

 

I wasn't aware it was usually the fuse panel.
it was on first one I dealt with. Rest been just the gem.
Im guessing maybe not on this 97 I haven't dug into.
​​into.just know I have the original burned up gem.
and it gone fruit loop. Still think engine cutting completely off for split seconds or 3 seconds is ecm.

 

Ford calls the control computer a Powertrain Control Module (PCM). Might help any searches. It's on the passenger side of the vehicle. I haven't heard/read much about leaks over there. Only the GEM/fuse panel seems to get wet from a leaking windshield.

Your pictures look a bit like you do some mudding and might have hit some deep water.

 

For what it is worth, I just dealt with the same symptoms and thought it was most likely the GEM, when I watched a 4 minute video of a guy who fixed the switching module for the transfer case. It is the thing way up in the dash that will click like 5 or 6 times trying to engage the transfer case and stops when it finally gives up on trying to switch it unsuccessfully. It is easy to see if it is at fault. In my case I was able to reach in the dash and tap it with a screwdriver after switching into 4x4 on the dash, which caused it to work. Here is a link to the write up on the module I fixed...

https://www.ford-trucks.com/forums/1...crew-5-4l.html

Worth a try considering how difficult dealing with the GEM and fuse box. It caught my attention because you mentioned clicking, as in multiple clicks, in the dash. I believe it will only click once if it is successful switching the transfer case.

 

That's an informative bit there. I fixed my odometer same way. Just resoldered a joint looked exactly like that.
went from showing me wierd rolling snake. To actually showing it did in fact have 250k miles on it

My 97 is manual 4 x4 but relays clicking sounds from same area. I would guess the module is for your transfer case shift motor. I haven't tore into this base model f150 yet.

I plan to collect all these nice informative links.
assemble it into something we can all use. Later on a compressed comprehensive post 😀

 

You may be right about someone and deep water..
Offroading #1 thing to do around here.
Glacial silt real killer on everything. will eat brushes up on alternator will destroy wheel bearings. Ect.
i'd never buy a pickup that looks like mine.
that gray mud huge red flag.
wasn't like that when I got it. But had the issues.
the engine cutting out only thing that worries me.
Usually just like a quick on off on off. Couple times its was a few seconds. And me already imagining the tow bill I can't afford. Maybe I will try pressure washing around windshield and cowl and see if I can find water intrusion.

 

What state are you in?

 

the best one? Lol Alaska.
its raining today. Went out and plain as day my floorboard wet. Water right off the gem/fuse panel.
never seen it actually wet or Dripping before.
🤦

 

Yup, when it rains good here in Oregon, I go out to the truck and sometimes find a puddle on the front floor mat and a wet mark on the brake pedal.

 

I knew it was the gem. working on getting a windshield.
Hopefully I can cut a used one out of the 3 other expedition I have. Don't want to sell my problem off. But. Ughh. New windshield 325-395$ install used one if I can cut one out. Want 215$ but they seemed knowledgeable about this era ford leaking windshield. Offered me upper molding for 25$ and goto parts store for urethane.
I have some experience and a friend with the tools.
Hopeful to save its fuse panel. Gem im gonna guess need to replace. And then maybe can answer myself on is the gem/fuse panel causing the cut out of engine 🤔

 

Removed fusebox. And here we go. Have not seen anyone say what size drill bit to use on them studs to open the box. Seems to be a 1/2" Also some take the fuse holder part apart. I did my first time but my high beam headlamp fuse holder was burned.