Good afternoon all,

I am hoping someone here will be able to help me because thus far my local dealership has not. I am looking for contact information for the Regional/Zone Manager for the Loiuisiana area or anyone else who would be able to help in resolving the latest electrical issue with our 01 Expedition. This latest electrical issue is with the Kelsey Hayes ABS module which has malfunctioned after a heavy rainstorm. The service manager at the dealership is stating that it was caused by a leak in the windshield and will require $900 + to repair not including the reseal of the windshield. With all the prior electrical gremlins we have experienced we have never seen evidence of water inside the vehicle or fuse box before. The service manager said that he has been in contact with the zone manager and that they can do nothing to resolve it and that we are going to have to pay to get the vehicle repaired. Our ESP coverage will not cover the repairs because they are due to a water leak (how convenient). The vehicle is still at the dealership and I am waiting on Ford CRC to follow-up but don't know where else to look for help.

Any advice/help/information that anyone would be able to provide me with will be greatly appreciated.

Thanks in advance

PJ

 

You might ask them to explain how a windshield leaking water would cause the ABS module to go bad. It is not under the dash, it's in the engine compartment.
What do you mean when you saythe ABS modulemalfunctioned?

 

The windshield leak ran into the fuse box & GEM module which sent out electrical current which this time affected the Kelsey-Hayes module. We have hadSUV back to same Ford dealership 5+ times over the life of the vehicle just for strange electrical gremlins and not once was anything ever said about the fuse box being wet or water intrusion. Norhave we ever witnessed water inside thefuse box ourselves.This last time, after a heavy rain,the SUV wouldn't start and had to be jumped. That's when we heard the clicling/popping noises coming form the Kelsey-Hayes module along with the dash ABS indicator light on and so we immediately took it up to the dealership so their tech could witness it firsthand and not subject us to the "Could Not Duplicate" answer as in previous times. The ABS module malfunction isa majorsafety concern that you would thinkFord would want to address.The dealership will not give us the Zone Manager's name or any other higher upcontact infoand itappears they plannot totake any action to resolve the situation other than us paying $1000+ to have the issues fixed.

The Ford Customer Relations Center sent a polite e-mail stating "Thank you for contacting the Ford Motor Company Customer Relationship Center regarding the electrical concern on your 2001 Ford Expedition. We have reviewed your situation, and there are no warranties, recalls or customer satisfaction programs on your vehicle that would provide assistance for this repair. If you have any other inquiries, please feel free to contact us and we will be happy to address them for you."

Wehavefiled a complaint with the NHTSA and ourlocal Attorney General's office.If anyone has any other advice/suggestions on what steps to take nextor if you have been in a similar situation we would appreciate hearing about it.

Thanks in advance

 

I've got the same situation in my 2000 4wd XLT
I had problems with the electrical system: (radio shorting out: wipers not working etc.) Took it to the dealer--same cost estimate as you mentioned for repair: I took my truck to a windshield specialist and had them test the windshield:--no leaks:--so it appears that my dealer was too lazy to check gaskets etc for leaks:
I have had water in the fuse box and gem module--even felt it drip on my foot once or twice during heavy rain:
Currently I'm locked out of my car because the power locks won't work and when I put my key in the lock, the cylinder just spins:

This is certainly an issue that ford should address:

 

My 97 had ABS lite , radio playing ,door locks not working,gauges pinned out ,and running board lites on all with no keys in truck. Dealers finding that a bad GEM module but no leak.600 hundred dollars.It was good for about two months,then a heavy rain and it starts all over.Back to the dealer .They found water in the fuse box ,replaced windshield because it cant be removed and resealed without damage.New gem module and 285 dollars. There a statement about leakage on ford sites but no cash from them. good luck

 

It's been a few months since the last post here, so let me know if you already solved it but...

The GEM may be getting wet due to a leak in the door hinge, possibly the windshield.

My experience:
Some time ago (months), I had some strange issues with my 2000 F150 Lariat. These include wipers coming on with the switch off, radio not working,relay action with the key off, 4X4 light flashing, etc... I removed the GEM+fuse box assy and looked for any visible damage. None found. (Dry by then)

Then this week, my truck was parked in the driveway during heavy rain overnight. It would not start in the morning and there was a little water on the floor (dampness on a small spot in the carpet). That evening, I removed the GEM and blew it out with compressed air, reinstalled it and the truck started.

Then, I hosed down the windshield and hood for 5+ mins to simulate the heavy rain and found a leak that was possibly from the seal on the door hinge. My best guess is that water dribbled down the harnesses and seeped into the GEM. I have not ruled out the windshield yet.

Now I will reseal the door hinges and inspect the windshield seal.

This is time consuming, but you can also pay someone else to do it. I think this will solve the problem. Also check the ports that are available to run wires through the firewall, they could be open.
Do not mess with the GEM or any other electronics with the battery connected.

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You got it right.Ford wont pay for this. faulty windshield seal/install.You wont neccesarily see evidance of leak,but it gets in behind fuse panel and into GEM. removal/cleaning and reseal winshield is the only fix.