Guys, bear with me, this might get long and rambling but I had a host of electrical problems suddenly this morning on my '01 EB and I need to get your input.

First, note that this is the first indication of any of these problems. None have surfaced before in any way. It is a rainy morning here in MA and the temp was about 38 when I went out the the truck and started it up. The problems happened almost immediately.

The first thing, after the truck had been started for maybe 10-15 seconds, I started hearing beep tones coming from the instrument cluster. They were grouped together, at first 3--beeeep, beeeep, beeeep--with no warning lights showing. Then I turned the wipers on, front and rear to clear the windows. They swiped a couple times, then stopped. I turned the truck off, started it back up, they worked again, then stopped again.

I got more tones from the cluster, this time in groups of 5 or 6 beeps. Still no "check engine" light or any other warning indicator. Engine seemed to be running okay.

I got my daughter in the truck, and we headed out onto the road on the way to school. Still raining, we get 20 feet out of the driveway, the wipers stop again. Now the power windows won't operate either. However, radio is still on, and hazard flashers are working. I pull over, turned it off, then on, and wipers are back.

As I accelerate from that stop, a few cluster lights flash--the 4x4 (though it did not engage the actual 4x4), and a few others. They did go away, but the wipers/windows thing happened a couple more times on the way to her school. Funny thing was, it seemed to be affected by speed or perhaps RPM, but I'm not sure. When I would pull over, get the wipers working again, take off back onto the road, they would stop working around 20-30 MPH. The when I would brake, and go from 35 down to 30, they would start working again. Weird.

In any case, the problem eventually stopped long enough for me to get her safely to school, and then I headed to work. Timeframe--20 minutes.

When I shut off the truck to bring her into school, the heater stayed on--it had power and was blowing, even though I had the keys in my hand.

When I was at a red light after this happened, the beeping returned, with it mostly being a series of 6 beeps together. It's like the beep when the low washer fluid light comes on.

I parked at work, and the heater still ran after turning the truck off.

I've seen a few similar things here, but I want to check with you guys for sure--does this sound like my fusebox is all wet (I haven't opened the hood yet for fear of worsening it) or is this perhaps the GEM module going bad?

How bad is this going to hurt?

 

Replying to my own post here...

Okay, just found this elsewhere on the board here:

"The GEM controls courtesy lights, wipers, power windows, 4x4 operation etc.
It's all in the module bolted to the back of the fuse box."

Seeing how I saw a problem with the wipers and 4x4, the GEM is looking like it might be the culprit here.

Now, for those with experience here--does this typically mean the GEM is bad or going bad, or could it just be getting wet and maybe all i need to do is WD-40 it to get rid of the moisture?

 

It sounds like your Gem. I had to replace mine completely, the shop said it was shot. I do not think i would spray an electgrical component down with WD40 though. i think you might be asking for a fire.

 

Repetitive beeping in cycles could also be the backup system that warns of a defect in the airbag system. This backup system usually only works if the airbag warning light in the instrument cluster is burning out. Does sound as if your primary problem is a bad GEM.

Before you run out and replace it, be certain that the area in which the GEM is located, behind the underdash fusebox, is not experiencing a water leak. Been more than a few cases in which a leaky windshield gasket has fried a GEM. I don't think that you want to pay for one twice.

 

In my situation, My windshield was not leaking. I asked the technician to make sure and he said he was positive it was not leaking. that was over two years ago and it has been fine every since.

 

If the heater won't shut off the problem is usually the under dash fuse box is shorted inside. The GEM doesn't control the heater. You might end up replacing both the GEM and fuse box.
Try blowing out the fuse box with compressed air and see if that makes any difference. Sometimes just wiggling the fuses will change things. You can sometimes here arcing inside when you do that.
Like PaulC said make sure you don't have a leaking windshield or you'll be buying the parts again soon.

 

Well, I've bought the GEM module. It was dark when I got out of work, but I pulled the fuse cover off under the dash and felt quickly for any obvious wetness. None was apparent, but I'm pretty sure if there is moisture in there, it's up above/behind the visible fuses.

I'm going to pray I can get through tomorrow with it and going to see about putting the new GEM in Saturday. I know the GEM is behind or above the fuse panel--do I need to remove the fuse panel to get to it? The Haynes book is silent WRT to the GEM, except having it in various electrical diagrams. The GEM module I bought is encased in hard plastic--would there be any benefit to sealing it up before installation?

I'm going to try the compressed air thing too... How bad of a job is replacing the fuse block (aside from having to put all the fuses back into place...)

(BTW, Racerguy, I read elsewhere here that the GEM does control the blower. I did call it the heater, but it was in fact the fan blowing. Was this erroneous information?)

 

Welp, wonderful. I just opened the instruction paper that came with the GEM and it says that this thing has to be programmed with data from the old GEM before installation using some kind of Ford tool.

Looks like I'll be paying the dealership for this work after all. Dammit...

 

Usually the GEM doesn't have to be configured. The worst that will happen is that you find it does and have to drive to your dealer and get it done. They don't need the old one to configure the new one. They can download "as built data" to configure the new one. Like I said though it shouldn't need it.
The GEM comes out with the fuse box. Remove the big dash cover piece under the steering column and then unbolt the 2 big connectors on the back of the fuse box. They have 10mm head screws. Next remove the 2 nuts and 2 bolts that hold the fuse box to the dash. Lower the fuse box enough to unplug the GEM connectors on the left side of it and then remove the fuse box and GEM. It's a tight fit.
This is what the shop manual says about the GEM......


The GEM controls the following features:

wipers/washers (front/rear)
warning chimes
battery saver
illuminated entry and courtesy lamps
driver power window
accessory delay
four-wheel drive
heated back window/mirrors