G.E.M./Fuse Box Removal, Disassembly, & Fix! / Water Leaking On Body Control Module! 1997-2003 F-150

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In this video I am showing you how I removed, disassembled, cleaned, sealed up, and re-installed my GEM/body control module on my 2003 F-150. This applies to all 10th generation F-150s, which range from 1997-2003.
Just like I said in the video, to fully fix the issue you’d want to also re-seal your whole windshield.
I hope it was helpful!
TIMESTAMPS:
0:00 - Intro/Symptoms
6:22 - GEM Removal
12:00 - GEM Disassembly
19:02 - GEM Cleaning and Sealing
27:25 - GEM Reassembly
32:32 - GEM Reinstallation
36:14 - Final Testing
39:13 - Dash Reinstallation
40:37 - Outro
Tools used in this video:
- ¼ Inch Socket & Ratchet Set: amzn.to/316vN9s
- Trim Tool Set: amzn.to/3VK2UdJ
- Small Torx Bit Set: amzn.to/41fTCXT
- Silicone Spray: amzn.to/3NIG7Ni
Other related videos:
- 2003 Ford F-150 Intro: • I Bought A 10th Gen F-...
Please note that I am not saying that you have to do exactly what I say or do in this video. This video is only a guide to show you the steps I took to do the job. Perform these repairs at your own risk! Safety first!

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6 июл 2024

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Комментарии : 126

@JohnM51982 Месяц назад

Your patience for this is amazing.

@AutoFixYT Месяц назад

Thank you! I kind of had to have the patience, i had no other choice haha but I also wanted to show people how it's done.

@flynn1727 5 часов назад

The fact you don’t have more likes on this amazes me 🤯 amazing video man

@texascubs3676 9 месяцев назад

Best in-depth video on this issue. Well done, and thank you.

@AutoFixYT 9 месяцев назад

Thank you!

@sigwater7326 4 месяца назад

I want to say thank you for making this video. I never new what a fuse box looked like inside and certainly would not have attempted to take it apart without seeing this done. My ford had the same issue and I successfully took it apart and fixed er up. Thanks again. I will make one comment for others who are going to do this. I did this in reverse order, meaning I set each panel on top of the other so I could set the metal pieces in place without flipping them over. You have to snap each metal piece in place and that is much easier to do if the black insulator panel is set in place first. This way was much less of a fight for me. Cheers.

@AutoFixYT 4 месяца назад

That's awesome, thanks for the comment! And I'm glad the video helped!

@dojonishi2222 7 месяцев назад

Great video! Thank you ! I followed exactly what you did and now everything is functioning as it should. It took me a few hours to take it apart, clean and reassemble. It was surprisingly fun to do. Thanks again.

@AutoFixYT 7 месяцев назад

Awesome, glad the video helped !

@jhillwine 4 месяца назад

Excellent video - I especially needed help with removing the fuse box/GEM. I found one small enhancement for your consideration - remove the lower driver's side kick panel to allow access to one more bolt that holds the metal bracket. Removal of this bolt allows an extra 1/2" that is helpful when removing (and especially when re-installing) the fuse box/GEM. Thanks for your help.

@AutoFixYT 3 месяца назад

Very good tip, thank you!

@williamcaddell6493 7 месяцев назад

GREAT video! Really well done. Edited perfectly. Helps solve my problem. Until this, I didn’t have a clue how to fix. Thank you!

@AutoFixYT 7 месяцев назад

Thank you! Glad it helped!

@georgetoney9964 5 месяцев назад

Thank you for your work on this video. My 2001 was having problems similar to your video. Took out the fuse box and didn't see much corrosion. Then looking closer at fuse block found some green stuff. Followed your instructions on how to disassemble the block and found water inside. Thank you once again. Now time to have the windshield fixed

@AutoFixYT 5 месяцев назад

A very annoying issue to have and too bad these trucks have this issue. But if you know how to fix it it's not all that bad in the end. The trick here is to catch it in time, before it ruins things.

@augi02 6 месяцев назад

Thank you! Just had to go thru this on my 02’ and this video definitely made it less stressful

@AutoFixYT 6 месяцев назад

Glad it helped! It's too bad these trucks have this problem

@Dimbochan 11 месяцев назад

I have the exact same problems and plan to get a used fuse box from a salvage yard. This video is the best on exactly how to remove the fuse box and GEM, excellent explanations thank you so much!

@AutoFixYT 11 месяцев назад

Awesome, glad it helped! Yeah get a good fuse box in there if yours I'd bad. Also, make sure you seal the windshield so it doesn't keep getting water in there lol

@paulsosa1872 5 месяцев назад

Amazing attention to detail you sir are a real mechanic anyone else would have just thrown a new fuse box in this truck 💯👍💪

@AutoFixYT 5 месяцев назад

Thank you! The way i see it is this repair was free and a new GEM module is expensive lol

@paulsosa1872 5 месяцев назад

@@AutoFixYT I think I'll have to pull the fuse box out open it up and take a good look at it. My wipers don't turn off and the AC blower stays on after a heavy rain. I'm suspecting its this box is getting water in it.

@AutoFixYT 5 месяцев назад

@@paulsosa1872 yup, guaranteed that's what it is

@samuelrulloda8570 2 месяца назад

I’ve got exactly the same problem with my 2003 Triton model. The only difference was it burned my starter running with the engine while in an ON position. Very wierd. I thought it was a faulty ignition switch and ignition cylinder which I replaced but man, I still burned 2 starters in one day trying to fix it, so I ended up making a separate toggle switch for my starter motor😁😁. Thank you for your patience making this video. 🙏🫶🫶🫶 New subscriber here.

@AutoFixYT 2 месяца назад

Wow, that's crazy but I'm not surprised. I was afraid something like that would happen to mine if I didn't fix it quickly. But good call on the manual starter switch hahaha

@billycav75 8 месяцев назад

Thank you. You saved me a lot of trouble. I was having same problems my windshield leaked a few years ago i thought i got lucky. When i got all the corrosion fixed started blowing fuse for the radio and dome lights.Found the under the hood light was causing that.

@AutoFixYT 8 месяцев назад

Crazy but at least you figure it out!

@douglaswood3569 6 месяцев назад

I accidentally discovered this. I have a 99 + 02 f-150 similar problems. Thanks!

@AutoFixYT 6 месяцев назад

I'm glad it helped! It's a very annoying issue and too mad that it affects these trucks like this. On mine it aurally rotted the floor board from having water dripping on the carpet

@andrewrogers5799 2 месяца назад

that was pretty fricken amazing to watch

@AutoFixYT 2 месяца назад

Thanks haha

@jamesblackwell5141 2 месяца назад

Thank you for the video and your hard work. Made my job much easier today!

@AutoFixYT 2 месяца назад

You're welcome! This was the idea in making this video, to help others solve this problem easier.

@pl5624 5 месяцев назад

Great video.i drilled holes in the bottom of my gem to help drain out any water as well...

@AutoFixYT 5 месяцев назад

Not a bad idea but better to prevent water from getting in there in the first place haha

@calebcannon4653 5 месяцев назад

My 99 F-250 is intermittently having similar issues. I have noticed a small drip near the fuse box too. From the looks of it, the fuse box and GEM are very similar. I'll keep you posted on if this fix is applicable to the Super Dutys too. Excellent video man. Keep puttin' em out! I'm sure you've got a lot of hours into editing/shooting and it shows.👊

@AutoFixYT 5 месяцев назад

I would bet that you're having the same issue even though it's not the same truck. It sounds too similar to be anything else. But yeah keep me updated! And thanks! I have a couple others planned so stay tuned I guess haha

@davidlester9432 11 месяцев назад

👏👏👏great job my friend. You were mine mentor today. Got my gem out today....letts see if I can make it shine...

@AutoFixYT 11 месяцев назад

You got this! Glad this helped!

@AskJesusLeon Год назад

WOW I thought your video on rebuilding the PSP for the Honda was intense this was a just bananas! I have to give you an A+ for patience my friend. When you were doing and undoing the metallic leads, yeah I would have lost it! 😂😂

@AutoFixYT Год назад

Haha thank you! This was an experience for sure! I learned how fuse boxes are assembled haha to be honest, I had no idea it was layered like that until I took it apart. But hey it fixed my issue and I even saved the old fuse box!

@jesusleon1153 Год назад

@@AutoFixYT Great job! Have you had anymore issues with water coming into the truck? Are you going to reseal the windshield soon?

@AutoFixYT Год назад

No more issues with the fuse box at all! And yes I will reseal the windshield soon.

@terrylewis4302 11 месяцев назад

Great video man,i just had to do the3 same thing to mine,damm window seal

@AutoFixYT 11 месяцев назад

Yeah, bad design but what can you do…

@rudy6458 Месяц назад

Great video, wish i had your patience.

@AutoFixYT Месяц назад

Well... i didn't have another option haha but also it was a learning experience for me.

@benmiller8942 8 месяцев назад

Yep...so glad i came here....having many of the same things happening...windows, headlights, 4x4 lights. Just crazy.

@AutoFixYT 8 месяцев назад

Yeah take care of it before it gets worse!

@benmiller8942 3 месяца назад

Hey, just curious what size is the drill bit you used in the beginning of the video...thanks.@AutoFixYT

@AutoFixYT 3 месяца назад

I don't remember, but if you have a drill but set I'm sure whatever the largest one is will do just fine. Maybe a 1/2 inch?

@moegenuisgar7297 5 месяцев назад

Imgoing through it now wow thanks 03 f150 5.4 v8

@AutoFixYT 5 месяцев назад

Good luck!

@jaredscott3845 9 месяцев назад

I’ve been having the same exact problems with my 1998 f-150. You went very in-depth and I really appreciate that. I’ve been pretty much freaking out cause this is my only vehicle to get to and from work. So as soon as I get home tomorrow I’m going to do exactly what you did in the video. I will follow up in this comment section to let you know if it worked. Fingers crossed. Thank you for taking the time to post this video.

@AutoFixYT 9 месяцев назад

Thank you! And I'm glad the video helps! Yes definitely let me and everyone else here know what you found and whether it fixed it or not. If you choose to disassemble the entire module like i did just take your time so you don't break anything or lose any little pieces. The trickiest parts were drilling out those inernally threaded bolts/studs to get the module apart, as well as disassembling and reassembling all the panels/layers of the GEM. That was also the most tedious and annoying part. My finger tips hurt so bad halfway through from pressing the conductor plates back on that I started having to use pliers. You can do it!

@Sig-manFraud 8 месяцев назад

I have a 05 and my lights come on intermittently, let me know how much of a P.I.A. it was so I know how to spend my weekend...

@davidlester9432 11 месяцев назад

Many thanks ...I know this is my problem too....u do it i can do it

@AutoFixYT 11 месяцев назад

You can do it!

@eggbertfarnsworth5787 3 месяца назад

Hey! I use the same battery positioner tool you do! LOL. Great video! I have my GEM/fuse box out right now, but no sign of water. Am tracing down a parasitic drain when truck is off. Odd, it goes away if I remove two fuses from the GEM, but one at a time... either one... and the drain stays there. I started to take the fuse block apart, but didn't. Your video gave me confidence to try again. T-Y.

@AutoFixYT 3 месяца назад

Thank you! As for the draw, it's always annoying to figure this stuff out... keep in mind draws can take a long time to settle down to a number. Thankfully these trucks are old-ish and simple so there aren't many electronics that should run in the background.

@lubosvanek694 Год назад

professional!

@AutoFixYT Год назад

Thank you!

@DavidMiller-bp7et 4 месяца назад

My 1999 Epedition had same issue. I replaced the GEM with a rebuilt one. Still leaking around the top of windshield; keeping it tarped until I can get it replaced. Coastal Oregon is really wet. Thank you for the video; as well done as any I have seen. Fun music and sound effects are helpful. The new module plus labor was over $1000. Bad elect design, I surmise; but I do love the way the Expo rides. Really comples GEM design.

@AutoFixYT 4 месяца назад

$1000 is crazy for the GEM. But im glad you got it fixed!

@DavidMiller-bp7et 4 месяца назад

Yeah, still have a parasitic draw with 2 circuits, will fix those. Crazy stuff when that electric brain starts shorting out. It would have been just as much to fix it like you did. Many hours of labor. The video was really high grade.@@AutoFixYT

@AutoFixYT 4 месяца назад

@DavidMiller-bp7et Yes it took me a few hours in total for sure. But since I had the time and I had all the tools I saw this as a free fix, as opposed to several hundred to replace the module

@DavidMiller-bp7et 4 месяца назад

My great mechanic goes at $100/hour so it gets close to a grand anyway. This seems to be a common issue with Fords of this vintage. I found the 2 circuits with parasitic draws, one of them, #15, includes the GEM. Hope it's something else on the circuit which is crowded. #16 looks easier with less stuff on it. If I had unlimited time and didn't need this as a 2nd car I "might" have undertaken it. Thanks for your very sensible comments.@@AutoFixYT

@AutoFixYT 4 месяца назад

Yeah $100/hour is typical, sometimes actually on the lower end of rates depending on where you live. Hopefully you can get those parasitic draws fixed!

@pdx_angler9760 2 месяца назад

Wow... what a PITA. You have way more patience and persistence than I do. What a weird design and bad accessibility. I see where they were going for low cost and low IR drop with stamped metal conductors but there must be a better way.

@AutoFixYT 2 месяца назад

It is what it is, that's all i can say haha I bought the truck, I needed it, and I had to do it. I did not have another option. But yeah it was an annoying process.

@bucksnortbumblefuk6872 Год назад

That's all that's in them??!! How come places say, reprograming?? I'm gunna definitely be taking mine apart. No biggie. Can't believe you don't have more likes. Great work!!!

@AutoFixYT Год назад

Thanks! Maybe some other models need reprogramming, or especially newer ones. Also, if you are replacing it you're more likely to need it reprogrammed so it can retain the functions that originally came with that truck. Just taking it apart won't do anything to it

@bucksnortbumblefuk6872 Год назад

@Auto Fix mines a 99 f150. 4wd issues. I've ruled everything else out. Odometer comes and goes Door dinger comes and goes Pretty sure it's the gem, or fuse panel. Either way I'm gunna pull it and also take a lookc. Again, nice vid.

@AutoFixYT Год назад

@@bucksnortbumblefuk6872 Yeah that sounds like a GEM issue. Pull it and see what you find! Just so you know, the GEM is actually the smaller unit that screws onto the back side of the whole fuse box. It's the thing I had to use a torx bit for. The rest of that assembly is the actual fuse box. However, a lot of times they are sold together and the two end up being referred to as the "GEM" together as of they were one unit.

@jollygreen1100 11 месяцев назад

Super awesome video!! My question is how long did this whole process take you? I have a 97 with numerous oddities like door dinging when no key in ignition, no wipers, no radio. Thanks for the great video!!

@AutoFixYT 11 месяцев назад

It took me several hours to do it all. Hope you get your issue figured out!

@russ_vee_jr4199 9 месяцев назад

Excellent video! The Side-View Mirrors and Driver's Seat Motors stopped working some weeks ago on my 2000 Excursion. Both are powered through the GEM but go through the USM (Under-Seat-Module) for their 'Memory' functions. All connectors are in place. ARRGGG! Double ARRGG Even!! What's a Guy to Do? I really don't want to disassemble the GEM, like our great poster did, but I will if need be. Several years ago, I repaired a Corroded-Thru Ground-Wire that powered the USM to get the Power-Seat to work. Maybe I'll luck out again with a similar wiring problem......

@AutoFixYT 9 месяцев назад

Unfortunately the best way to go about this is to test for power in different places to see where you are losing power. Fuse, relay, GEM, USM, grounds, etc.

@russ_vee_jr4199 9 месяцев назад

Yup. You're Spot On Sir, and that's how the USAF taught me how to troubleshoot the Titan II ICBM Launch Control System 60+ years ago and that's how I fixed the 2000 Exploder's Power Seat 7+ years ago. The seat is where I originally positioned it, and it can stay that way for ever more. The mirrors are positioned for driving, but I like to angle my side out when merging into traffic and down when backing. I've had more pressing problems/projects than this one, but it's now been elevated to #2 on my 2Doo-List. Thanks for your reply. You are exactly correct, and I'll do just that after I move all my Stuffs from my old storage facility to my new one........

@ericstites9470 4 месяца назад

I just dismantled and cleaned all the parts to the fuse box on my 97 Eddie Bauer. Couldn't have done it without watching you do it first, very grateful for this video! One question - did you just use the silicone spray in between the panels? I've got all mine assembled and ready to put back together, just curious on how to best go about keeping water out for good(windshield is already sealed).

@AutoFixYT 4 месяца назад

Thank you! I did use silicone spray between all the layers, yes. But that was just an extra safety layer and also to prevent corrosion from humidity in the air. If your windshield was already properly resealed, no water should get in to the fuse box.

@mrdudeperson449 11 месяцев назад

I've had weird problems like this exactly all of what you have and also sometimes in heavy rain my starter motor will spin up with my keys in my pocket.

@AutoFixYT 11 месяцев назад

Yup, sounds like a typical GEM issue. Get that fixed before it catches on fire if it's sparks up in there!

@clawhammer704 Год назад

After replacing I would put plastic wrap and sealer on top of the gem and fuse box to keep water at bay.

@AutoFixYT Год назад

I don't think plastic wrap is a good idea because it prevents air flow. Spraying the internals retains the air flow and cooking properties as it was designed, but adds a layer of water resistance that wasn't there before. Also, like I said, ideally you wanna stop the leak in the first place.

@davidlester9432 11 месяцев назад

Very crappy ford design...Aerostar was the queen B

@mid-westbigfootresearchers8665 7 месяцев назад

I'm still stuck on getting the fuse box to slide down as I write this, and have wathed this video over and over in that part, you don't show what you are unplygging from the back to make room for the fuse box to slide down. I'll figure it out, but I don't unplug stuff that I can't see...I need to know so I can make sure I plug stukk back in right. Video helps more than others, thanks.

@AutoFixYT 7 месяцев назад

I just watched the video and it seems to me that i showed everything you need to disconnect to get this out. It was however a very tight fit, and you have to make sure it's not getting caught on any wires in the back. On the back side the only two connectors I disconnected were the two main harnesses with the 10mm bolts. On the left side you have three plugs, and on the bottom there are some retainers to pop off for other wires. That's about it. Other than that it's all about how you maneuver it out of there.

@juanyoremeseri6822 3 месяца назад

this is not a simple job, many people can not do this but is a good option to save money. thank's to show the way to do it,

@AutoFixYT 3 месяца назад

Agreed, you have to have some knowledge as to what you're doing and lots of patience with this one. But for me it was the only option. Plus I was able to film it and share this with everyone because I knew there were many out there that needed help with this. I did too. But I had to compile my own information from many sources, and put it all in this one video.

@alex5390 6 месяцев назад

Ohhh boy this should be fun. My 2002 F150 was leaking through the front windshield after a windshield replacement. Relay #1 keeps glitching out with the interior lights and who knows what else. I saw in a comment you said it might need to be reprogrammed if swapping the whole box from a junkyard? Is that correct? But you also said pulling a part would be easier? So should I tear it down or could I jusy plug n play a new box from the yard?

@AutoFixYT 6 месяцев назад

Reprogramming may not be the case on these, although I did read something about it somewhere. So I cannot tell you 100%. If it were me I'd just take my existing one apart because a junkyard one could have the same issue. But yeah either way the issue is very annoying to deal with.

@Iseerightthruyou 10 месяцев назад

You dont have to remove the knee panel. You can just remove the bolts on the face, e-brake, and hood latch. You can carefully remove the fuse box and GEM module without disassembling so much of your dash.

@AutoFixYT 10 месяцев назад

Yeah, I kinda suspected that after I took the knee panel off but I was already committed so I wasn't gonna go back. Only a few bolts anyway.

@Iseerightthruyou 10 месяцев назад

@@AutoFixYT I sure am glad you responded.I didn't realize I had so many spelling errors in my original comment. I didn't type that, I was hacked..... 😂🤣😂🤣

@abrahamrodriguezalcocer7719 7 месяцев назад

Amigo de que año son compatibles las cajas de fusibles, tengo el mismo problema en una f150 2002 2000,2001 2002 y 2003 son iguales?

@alexandersantiago8796 7 месяцев назад

verifica manual de vehiculo,asumo es lo mismoi

@christianstevens6479 12 дней назад

Could this cause fuses to smoke and no brake light

@AutoFixYT 9 дней назад

Yes it can

@johnnypenner7006 10 месяцев назад

If you want an amazing battery/connector cleaner try coca cola i did this process and the coke ate through the corrosion no problem, just left the parts in it for a couple hours and didnt do much scrubbing after. Also thanks for the video, couldbr have done it without you

@AutoFixYT 10 месяцев назад

I will keep that in mind, thanks for the tip!

@TheDesertRat31 3 месяца назад

Yep. Coke has phosphoric acid in it. It's the same stuff in naval jelly, which is a gell used to remove corrosion from metal parts. The fizz action from the carbonated water helps too.

@jonmoul3131 6 месяцев назад

hey, do you know what the part number was on this fuse box? im having the same issues and im just going to buy a new one but i cant find a part number on google or anywhere.

@AutoFixYT 6 месяцев назад

I don't have a part number, sorry. Maybe you can source one from a local junkyard?

@ronnierussell5904 4 месяца назад

Ford no longer offers this part.

@tdkendall Месяц назад

Part# on sticker on fuse panel. Ebay has these, around $150

@devonhernandez1945 5 месяцев назад

Let me tell ya.... that module and fuse panel is more of a pain when you have a clutch pedal trying to help fight you as well 😂😅

@AutoFixYT 5 месяцев назад

Yeaaah i belive that! Haha must be 10 times worse

@umiami80 Год назад

this is amazing! How did you find the leak however? Is that still there?

@AutoFixYT Год назад

I found the leak by digging around and looking for it. I also looked up some stuff on various forums where people described their problem and it lead me to the GEM. No more leaks now!

@davidlester9432 11 месяцев назад

My truck leaked as well I heard it sizzling....😢🎉

@AutoFixYT 11 месяцев назад

Oh no! Fix it before it catches on fire!

@bert1913 5 месяцев назад

Ford= fix or repair daily...fix on race day...found on road dead...etc

@AutoFixYT 5 месяцев назад

Lol yeah, not my first choice of vehicle but the opportunity presented itself and I needed something this size so... whatever lol

@peanut71968 8 месяцев назад

So? Ford and other manufacturers go to millions of dollars to design these components and they still LEAK? Design flaw or manufacturing defect?

@AutoFixYT 8 месяцев назад

There are multiple causes and sources of leaks. The most common issue will be the windshield seal on this truck. They either dry up and stop sealing, or the water pooling up in the roof rails will break through the seal and start seeping in the cab. The right fix is to pull the winshield, clean up the old seal, the potential rust buildup, and reapply new sealant, and reinstall the glass.