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Discussion Starter #1
Hello Everyone,

New here to the org!!!

I have a 2002 SD Crew and had an odd problem with it yesterday; I have not had any problems with it yet until now.

Got in the truck yesterday and turned the key to start and noticed that the gauge cluster was dead, along with the radio, interior lights, and power windows. I found a blown 10A fuse so I put a new one in and as soon as I did it popped it immediatley. I stuck a jumper wire in there and could hear what sounded like a relay clicking. After doing that i stuck another fuse in and it didnt blow, turned the key forward and everything came on and then shut off again and the gauges started to reset but stuck all the way pegged on the other side....

I checked the fuse again and this time it had not popped so I assumed that I had a bad relay, I switched some relays around with no success so that debunked that theory.

After lots and lots of research online and on this site I have it narrowed down to 2 things.

1. The GEM has gone out due to a leak in the windsheild which is apparently a problem with these trucks, I read that someone talked to a Ford technician and 2002 F-250 SD do not have GEM's????

2. I also read that the gauge cluster can actually malfunction and cause all of this to happen.

I am going to look into this more when I get home from work today, any input will be greaty appreciated. Sorry for the story!!!! :icon_ford:
 

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Discussion Starter #2
Got home from work today, tore it apart and turns out it does not have a GEM module; unless there is a short somewhere than I am pointing toward the gauge cluster.

I am taking it to the dealership tomorrow, again, if anyone has any input let me know please.:dunno:
 

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It's a PCM, not a GEM. But not sure.
 

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As far as I know mine has a GEM. It's under the dash above the tranny hump. Look there with your head in the footwell by the pedals looking towards the tranny hump. U should see it. It has three plugs. No idea if this would cause the issue u r having just saying that the module should be there.


Sent from my fone. :)
 

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Discussion Starter #5
I just spoke with Ford parts and 2002 4wd have a GEM and the 2wd do not. All of the electronics for the interior are controlled throught the fuse box's internal (GEM) type module; at least that's what I believe. The new fuse box is $394.00 so I'm going to do some more looking around before buying that.:banging:
 

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Discussion Starter #6
So I pulled the fuse box completley out and took all of the fuses out, took the fuse box completley apart and BAM!!:woot: the circuit board is fried right where the relay and the fuse are for the delay powered accessory. I am picking up my new fuse box today.

Has anyone ever heard or seen a fuse box short out like that for no reason?

I have checked the O/D on/off wires in the steering column and also looked over all the wires in the dash as well, everything looks fine. This was not an intermittent problem, we drove it over an hour to my parents....got back in it to go to the store and POP:confused:....I will let you know what happens when I install the new fuse box.
 

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Discussion Starter #7
Fixed!!!

Picked up the new fuse box yesterday, it comes as a whole assembly....fuses, relays, power wire to the battery.....no wonder it was $400:crazy:

Anyway, I installed the new fuse box with the batteries disconnected and reinstalled the instrument cluster, connected the battery cables and saw that my interior lights and under hood light were back on....good. Disconnected the batteries and finished reinstalling the rest of the interior, connected the batteries again and everything works just fine!!!

Hope this helps someone out whenever this problem occurs...:icon_ford:
 

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I am having the same issue in my X. But I am getting the rapid clicking out of the relays. I also don't have any blown fuses. Did your theft light blink the entire time too? How about your door chimes? I don't have any power to the interior lights or radio either.
 

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I figured your fried the MB when you placed the jumper wire in place of the fuse. Not something I recommend doing, but glad you seem to have gotten yours back working correctly.
 
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