I did a lot of research on this topic before I decided on my course of action but found it a bit frustrating the lack of information available, specifically the lack on information on an actual resolution.

The Truck:
2002 Ex, 4x4, Limited, 7.3 PSD, 206,XXX

The Problem:
I bought my truck in February of this year (2025) and the truck had all the symptom of a failed vehicle security module (VSM). The door ajar light was on with all the doors closed (I even verified the door ajar switch in every door and the hatch went to ground when the door was closed), the dome light was off all the time and did not respond to the door being opened, the door lock buttons didn't work, the entry pin pad on the outside of the drives door didn't work. All the symptoms were there.

Research:
I called my local dealer to see if they could order a new VSM. Obviously the answer wasn't just no, it was hell no. Not in a decade, no. I did, however, get the newest part number for the most recent version of the VSM. 4C7T-15K602-AH. I took that part number to the trusty old Ebay and bought a tested VSM matching that part number for $131.69. I looked into the possibility of programming the module myself using Forscan, and while this may in theory be possible, I was unable to find conclusive evidence in the affirmative or any instruction on how to conduct the procedure. Because of that, I elected to have the dealership perform the programming for me. I heard through one forum or another that Bob Allen Ford in Overland Park, KS were experts at this type of programming procedure and were happy to share their knowledge with anyone possessing the gall needed to pickup the phone and give them a call. Cold calling people and the inherent potential of a stranger thinking you are a moron is one of my wife's greatest fears, but for me it is a non-issue so I picked up the phone can called the Bob Allen service department, informed them of their interwebs' fame, and asked them to divulge all their secrets of module communication. Of course, they had no idea what I was talking about. They did however, say they'd pass my name and phone number along to their parts manager and , guessing from their tone, they believed he was of the correct vintage to have some tribal knowledge and real world experience on these older trucks. A few hours later, Jeff Jenkins from the parts department called me and we talked a while about the module in question. He did have a little info to share but it was not some deep secret that Bob Allen Ford had taken years to crack. He passed along the TSB that I have attached for you here, totally free of charge, and indicated that method 7 or method 8 would probably get me where I needed to go. With my newly obtained information from Kansas I then visited, in person, 2 local Ford dealers to discuss the procedure and gauge their willingness to perform the work and their confidence in the chances of success. The 2 dealers I visited were Ford of Franklin, in Franklin, TN and Reiselman Ford, in Dickson, TN. Ford of Franklin quoted me over $300 just to try to program the module and seemed less than sure of themselves in the success of the programming. Chris at Reiselman Ford seemed to know exactly what I was asking for and, while he made no promises when it came to success, seemed to believe it would be easily accomplished. Their quote of $200, while still absurd for a simple module program (this is also what they charge to program a key, FYI), was at least a bit more digestible than Franklin's quote (those that live in Middle TN will not be surprised Franklin was 50% higher in price, everything is 50% higher in price in Franklin).

The Fix:
I tore my lower dash apart leaving the old VSM sitting on the trans tunnel, and the new module sitting on the passenger seat, and dropped the truck off at Reiselman Ford in Dickson, TN on a Thursday afternoon. By Friday around noon Chris called me to inform me that the programming was all complete, successful, and I could pick the truck up whenever I pleased. I went today (Saturday), retrieved the truck, paid the small ransom, and was delighted when I opened the door and the dome light came on. I went through the whole list of check outs right there in the parking lot. The doors all locked and unlocked with the switch on the door, they all locked and unlocked with the pin pad on the outside of the drivers door (yes, the pin pad code is now the code printed on the face of the new VSM, different from the original VSM's code), the headlights work in auto, and the door ajar light goes off when all the doors are closed. Everything seems to work as intended.

Hopefully this post gives some people some closure and confidence that a failed VSM can be resolved.

 

If you have a friendly fellow FTE member that has an NGS and an excursion, you could send them the good vsm and they can backup their configuration and restore it onto it. I have done that a few times.
Tim M

 

I believe this issue is common on the 2002 models only. The 2C7T version. It was fixed in the 3C7T and newer. So the restore from another 2002 with similar features will work. I did download the As-built data for my truck but was not able to use it with my NGS features. I heard that forscan can do the as-built restore.
Tim M

 

hmmm,
my VSM is also bad, did not know it could be programmed....
I just ignore the lack of interior lights, and that RED bulb states Door ajar...

 

Your VMS is probably no good and can't be reprogrammed. You will need to get a newer version and then get it re-programmed. I was at the pick-n-pull and grabbed the VSM out of a 2004 today. If interested let me know and I will updated it for you using the information from my Excursion. It would be cost of VSM and shipping. Send me a PM.

part number 4C7T-15K602-AH

When I fixed mine, I pulled the VSM out of a 2003 Excursion and did a backup of the VSM and restored it to a VSM I pulled from a 2005 F250 super cab. It fixed all my issues:
- door ajar light on console
= interior lights reversed
- radio staying on
- key pad not working
- door dinging when it shouldn't
- can remember what other issues I had.
Tim M

 

Thank you for the Offer, but I think I will forgo the cost.

#1, the Door Codes work just fine.

#2, it is an Ex-Fire Truck and the overhead lights have been replaced with a Manual Push on/off button, and they are super Sun Bright, LEDs, that light up the Corn Fields around the truck.

so, I doubt I would gain anything, except for getting rid of the pesky "door ajar" light.

 

I'm about to buy a VSM on Ebay. My 02 Ex limited 7.3 has a bad VSM after left rear door almost caught fire from the power door lock melting down. Can you program the replacement for me? Do you need the vehicle to do it? I live in WA state, and the dealership has no idea what I'm talking about. I'm looking at getting the 3C7T or 4C7T units instead of the 2C7T that it has.

 

If I sent you a 3C7T or a 4C7T, could I pay you to program it for a 02 limited 7.3 Ex? I can't find a local dealer that has a clue what I'm talking about.

 

Sure, I can assist. What I can do is take a backup of my VSM from my 2002 limited EX and restore it to the one you send me. I have not found a way with my NGS to restore using the “as built” file from Ford so this was my workaround when mine went bad.

Tim M

 

I'm curious. What hardware/software tools are used to save a backup of the VSM programming?

 

I am not sure what others can do it but I am using an NGS - Fords Next Gen Star programmer that was used during our generation of vehicles to do all stuff Ford. I don't have all the modules and abilities they had but I was able to backup a VSM and restore it to another VSM with success.

Here is my thread with my VSM issue.
https://www.ford-trucks.com/forums/1...rsion-vsm.html

Tim M

 

When I purchased my 02 v10 Limited X 4x4 a couple years ago I had the same issues. I found a replacement rebuilt VSM module from repairlaboratory.com. I had done all the research I could here and tried all the tricks before ordering the VSM. Upon replacing the VSM all issues resolved except the keypad door locks. It’ll lock the doors but I can’t unlock them using a code. Not a huge deal for me. I did NOT do any reprogramming or flashing of my old VSM to the new. Just providing this info as an fyi. It’s been about a year since I replaced it and all is still good. Thanks to everyone who posts here as this has been my go to place for info regarding Ex work. Happy New Year everyone!