2002 Ford F-150 Electrical System

Speed control deactivation switch

When it rains the rain is somehow getting into the fuse box under the steering column and causing it to drain the battery, short out some of the instrument cluster, make noise, blow fuses, and rust up. It is a fire hazard and it puts all inside the truck in danger. I have not yet had a fire but if I keep the truck as is it will eventually.

WOKE UP AT 1AM ONE 4-1-2018 TO MY FORD F 150 ON FIRE DRIVERS SIDE FRONT UNDER THE HOOD. UNKNOW TO US OUR LOCAL SHERIFF HAD SPOTTED THE FIRE AND ALREADY CALLED THE FIRE DEPARTMENT. TOTAL LOSS. BOUGHT THE TRUCK A FEW MONTHS BACK WITHOUT ANY KNOWLEDGE OF A RECALL ON THE SPEED CONTROL SWITCH. THE VEHICLE WAS SITTING IN OUR DRIVE NEXT TO OUR OTHER CARS FOR 3 HOUR WITH KEYS OUT OF THE IGNITION.

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT THE VEHICLE CAUGHT ON FIRE WHILE PARKED. THE CONTACT EXTINGUISHED THE FIRE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V017000 (VEHICLE SPEED CONTROL). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE THE APPROXIMATE FAILURE MILEAGE WAS 200,000. UPDATED 03/03/17*LJ *CN

I HAVE BEEN EXPERIENCING ELECTRICAL PROBLEMS PERIODICALLY OVER THE PAST TWO WITH MY VEHICLE(ORIGINALLY THOUGHT TO BE THE BATTERY), RANGING FROM HIGHLIGHT AND FLASHERS INTERMITTENTLY COMING ON WHEN THE VEHICLE IS LOCKED AND TURNED OFF. THE RADIO AND BLOWER MOTOR HAVING ISSUES AND THE INTERIOR DOME LIGHT COMING ON ANS STAYING ON. I HAVE ALSO NOTICED MORE AND MORE THAT THE WINDSHIELD IS LEAKING ON THE DRIVERS SIDE OF THE VEHICLE. I HAVE ALSO EXPERIENCED THE WIPERS AND HEAD LIGHTS LIGHTS SHUT OFF ONCE WHILST DRIVING ON THE HIGHWAY AT HIGHWAY SPEEDS DURING HEAVY RAIN.. THE MOST RECENT OCCURRENCE WAS ON THE 12/23/2016 AT MY PLACE OF WORK (NTB), ONE OF MY CO WORKERS NOTICED MY HEADLIGHTS FADING IN AND OUT THE RADIO COMING ON AND GOING OFF. WENT OVER TO THE TRUCK TO MAKE SURE IT WAS TURNED OFF AND NOT LEFT ON BY MISTAKE BUT THE ENGINE WAS OFF. SO I BROUGHT THE TRUCK INTO THE WORK SHOP TO HAVE A LOOK OVER THE VEHICLE AND DID SOME DIAGNOSTICS ON IT AND DISCOVERED MULTIPLE DEFECT CODES THAT ALL CONNECT THROUGH THE GEM(GENERAL ELECTRICAL MODULE) ON THE INTERIOR FUSE PANEL. UPON FURTHER INSPECTION I ALSO NOTICED BOTH THE GEM AND FUSE PANEL BOX HAVE GOT WATER INGESTION AND GREEN/BROWN STAINS COMING OUT THE BOTTOM. I HAVE DONE RESEARCH ONLINE ABOUT THESE'S ISSUES AND ITS A COMMON PROBLEM OVER MODELS FROM FORD FROM 98-03. THE FIX IS TO REPLACE THE GEM AND FUSE BOX AND TO RESEAL/REPLACE THE WINDSHIELD. NOW I BELIEVE THAT IS SAFETY ISSUE AND SHOULD BE ADDRESSED BY FORD THEM SELF'S REGARDLESS OF THE AGE OF THE VEHICLES AFFECTED BY THIS. HTTP://WWW.F150FORUM.COM/F12/LEAKY-WINDSHIELD-GEM-MODULE-PROBLEM-TWIST-98192/ HTTP://WWW.F150FORUM.COM/F6/GEM-ANSWER-ALL-MY-ISSUES-43475/

LOUD NOISE SPARK PLUG BLOW OUT AND CAUSED SPARKS WHEN OPENED THE HOOD. AFRAID IT WAS GOING TO CATCH FIRE SO HAD IT TOWED. ACCORDING TO MECHANIC IS A FORD ISSUE ONGOING BUT NO RECALL NOR WILL FORD PAY FOR IT. 91120 MILES ON TRUCK WELL MAINTAINED.

THIS IS THE SECOND OCCURRENCE OF THIS NATURE. THE PREVIOUS HAPPENED APPROXIMATELY IN JULY OF 2014. AT THAT TIME THE DEALERSHIP SAID THAT THE KEY WAS THE PROBLEM AND I PAID FOR A NEW KEY AND EVERYTHING HAS BEEN GOOD UNTIL ~ 1/4/15. THIS TIME, THE PATS (ANTI-THEFT) SYSTEM TRIGGERED AND RENDERED THE VEHICLE USELESS. AFTER ~ 45 MINUTES IT EVENTUALLY STARTED AND I DROVE IT TO THE DEALERSHIP. IT WAS THERE FOR 2 DAYS AND THEY COULDN'T GET THE SYSTEM TO TRIGGER. THEREFORE, THEY HAD ME COME PICK UP THE VEHICLE. TWO DAYS LATER, THE VEHICLE RENDERED ITSELF USELESS AGAIN THROUGH THE PATS SYSTEM. THE VEHICLE WOULDN'T START FOR 2 DAYS AS I TRIED TO START IT PERIODICALLY AS I WAS INSTRUCTED BY THE DEALERSHIP. FINALLY IT STARTED ON THE 3RD MORNING. WHEN I ORIGINALLY TOOK THE TRUCK IN THE TWO GUYS AT THE DEALERSHIP SAID THAT THIS IS A COMMON PROBLEM IN THIS YEAR MODEL. IN FACT WHEN I TOLD HIM OF THE ISSUE I WAS HAVING, THE SERVICE MANAGER ASKED IF I HAD A 2002 F150. WE HAD A GOOD LAUGH WHEN I SAID "YES, AND THAT ISN'T A GOOD SIGN THAT YOU KNOW THAT- WITHOUT SEEING MY VEHICLE." HE EXPLAINED THAT THE TILT MECHANISM IN THE STEERING COLUMN DAMAGES THE WIRE THAT RUNS FROM THE KEY TRANSPONDER AREA TO THE SENDING UNIT THAT TELLS THE ENGINE THAT THIS IS THE CORRECT KEY. THIS WAS THE NIGHT THAT THEY KEPT THE TRUCK FOR 2 DAYS. THIS IS A SITUATION WHERE A PERFECT OPERATIONAL VEHICLE IS NOT FUNCTIONING BECAUSE OF A CHAFFED WIRE OR THE WIRE HAS BEEN PULLED FROM ITS SOLDERING POINT. I AM THE OWNER, YET I HAVE THE SAME CHANCE OF STARTING THAT TRUCK AS A CAR THIEF. IT MAKES NO SENSE. THIS DIDN'T SEEM LIKE A SAFETY ISSUE TO ME UNTIL I WAS STRANDED FOR 45 MINUTES IN A PARKING LOT AND IT WAS EXTREMELY COLD. I ENVISIONED SOMEONE TURNING THEIR CAR/TRUCK OFF FOR SOME REASON IN A PLACE WHERE THE TEMP WAS WELL BELOW FREEZING AND FREEZING TO DEATH BECAUSE THIS SYSTEM HAS BEEN TRIGGERED. *TR

THE PROBLEM STARTED WITH THE VEHICLE NOT STARTING AND THE BATTERY APPEARING TO BE DEAD. BATTERY WAS REPLACED AND NOW THE ELECTRICAL ISSUES ARE WIDESPREAD AND OUT OF CONTROL. THE RADIO, WIPERS, DOME LIGHTS AND DASH LIGHTS GO OFF AND ON AND THE STARTER TRIES TO START THE TRUCK AFTER IT IS RUNNING. I HAVE BEEN LOCKED OUT OF THE TRUCK DUE TO THE LOCKS ENGAGING ON THEIR OWN AND I HAD TO PULL OVER IN A SEVERE RAINSTORM DUE TO THE WIPERS THAT ALL OF A SUDDEN STOPPED WORKING. IT HAS BEEN ROOT CAUSED TO BE WATER INTRUSION INTO THE VEHICLE FROM THE WINDSHIELD GETTING INTO THE FUSE BOX AND THE GEM MODULE IS NOW BAD. I HAVE RESEARCHED THIS AND IT VERY FRUSTRATING TO KNOW THAT THIS PARTICULAR VEHICLE YEAR IS WELL KNOWN FOR THIS ISSUE. I HAVE READ LITERALLY A THOUSAND COMMENTS OF PEOPLE HAVING THE EXACT SAME ISSUE WITH NO RESOLUTION FROM FORD. NO RECALL WAS ISSUED AND WE HAVE TO SPEND A LARGE SUM OF MONEY TO FIX A KNOWN ISSUE WITH THIS AND SIMILAR VEHICLES. NOW THE FORD DEALER IS TELLING ME THE GEM MODULE HAS BEEN ON BACK ORDER FOR MONTHS AS THEY ARE RESOURCING THE PRODUCT, SO I CAN'T EVEN GET THE PARTS TO FIX IT. I AM FORTUNATE THIS DID NOT RESULT IN A SEVERE ACCIDENT OR FIRE.

TURNS SIGNALS DIDN'T WHILE DRIVING IN COLD VEHICLE IN COLD WEATHER. ONCE THE TEMPERATURE WARMED UP THE INSIDE OF THE VEHICLE THE TURN SIGNALS WORKED NORMALLY. I HAD NO PROBLEMS IN THE WARM MONTHS OF THE YEAR. TURN SIGNAL LEVER WORKS PROPERLY ON AND OFF. THOUGHT IT WAS THE FLASHER UNIT, REPLACE IT AND HAD THE SAME PROBLEM. WHEN THE VEHICLE IS COLD ( SOMEWHERE BELOW 40 DEGREES FAHRENHEIT ) THE TURN SIGNALS DO NOT WORK WHEN STEERING WHEEL IS IN A LOWER TILT POSITION. THIS IS ESPECIALLY TRUE IF THE TEMPERATURE IS CLOSE TO FREEZING. WHEN THE CAB OF THE PICKUP WARMS UP SIGNALS WILL WORK. WHEN THE OUTSIDE TEMPERATURE IS ABOVE 50 DEGREES F SIGNALS WILL WORK. THE SIGNAL WIRES ARE STRETCHED IN THE COLUMN BY TILTING THE STEERING WHEEL DOWN. THE COLD MAKES THE WIRES STIFF. WHEN THE WIRES WARM UP THEY FLEX TO COMPLETE THE CIRCUIT ON THE TURN SIGNAL LEVER CONNECTION AND ACTIVE THE SIGNALS PROPERLY. THERE MAY HAVE BEEN A RECALL ON RANGER TRUCKS FOR THIS ISSUE. WOULD LIKE TO SEE ONE ISSUED FOR THIS TRUCK.

ODOMETER WORKED INTERMITTENTLY, SOMETIMES WOULD GO OUT AND THEN COME BACK ON. NOW NOT WORKING AT ALL. AIRBAG LIGHT STAYS ON. UPDATED 4/24/2015 *JS

THE TRUCK WAS PARKED IN THE DRIVEWAY AND CAUGHT FIRE AND WAS TOTALED. *TR

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT AFTER PARKING THE VEHICLE FOR APPROXIMATELY 30 TO 40 MINUTES, A LOUD NOISE WAS HEARD FROM THE VEHICLE. THE CONTACT DISCOVERED THAT THE VEHICLE HAD CAUGHT ON FIRE FROM UNDER THE HOOD. THE POLICE AND THE FIRE DEPARTMENT WERE CONTACTED AND A REPORT WAS FILED. THE FIRE DEPARTMENT ADVISED HIM THAT THE FAILURE WAS CAUSED BY AN ELECTRICAL ISSUE. THE VEHICLE WAS NOT INSPECTED BY A DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND CURRENT MILEAGES WERE UNKNOWN. THE VIN WAS UNAVAILABLE.

TL* THE CONTACT OWNS A 2002 FORD F150. THE CONTACT STATED THAT THE VEHICLE WAS PARKED IN A RESIDENTIAL DRIVEWAY OVERNIGHT WHEN A FIRE ERUPTED FROM UNDER THE HOOD OF THE DRIVER'S SIDE. THE VEHICLE WAS COMPLETELY DESTROYED. THE FIRE DEPARTMENT WAS CONTACTED WHO AND ARRIVED ON THE SCENE. THE FIRE DEPARTMENT CONCLUDED THAT THE FIRE WAS CAUSED BY AN ELECTRICAL ISSUE. A POLICE AND FIRE REPORT WAS FILED. THERE WERE NO INJURIES REPORTED. THE MANUFACTURER WAS NOT NOTIFIED OF THE INCIDENT. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 195,000.

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT VARIOUS WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE GEM MODULE FAILED DUE TO A WATER LEAK. THE CONTACT WAS ALSO INFORMED THAT THE MODULE NEEDED TO BE REPLACED AND THE WINDSHIELD NEEDED TO BE RESEALED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE VEHICLE WAS NOT REPAIRED BECAUSE THE NECESSARY PARTS WERE ON BACK ORDER. THE FAILURE MILEAGE WAS 103,000. THE VIN WAS NOT AVAILABLE.

COIL PACK CAUSING ENGINE TO MISFIRE. *TT

ELECTRICAL FIRE STARTING UNDER THE DASH AND ENDED UP TOTALING MY TRUCK. 2002 FORD F150. SUSPECTED TO BE CRUISE CONTROL SWITCH THAT WAS NEVER FIXED BY DEALER BEFORE PURCHASE, AND WE WERE NOT NOTIFIED ABOUT THIS RECALL. IT WAS SUGGESTED TO US AFTER GETTING THE INFORMATION TO THE INSURANCE CO. AND SERVICING THE FIRE REPORT TO DO SOME RESEARCH AND FILE A COMPLAINT/CLAIM. FIRE STARTED WHILE DRIVING DOWN THE ROAD WITH SMOKE COMING FROM UNDER THE DASH, THEN PULLED OVER AND GOT OUT AND FLAMES WERE COMING FROM ALL UNDERTHE DASH AND CONTINUED TO SPREAD TO THE ENTIRE VEHICLE WHILE WAITING FOR THE FIRE DEPARTMENT AND SHERIFF TO ARRIVE. *TR

MY HUSBAND PURCHASED A USED 2002 F150 FORD TRUCK BACK IN 2004. IN THE PAST 3 YEARS, THE TRUCK HAS MAJOR ELECTRICAL ISSUES EVERY TIME IT RAINS FOR MORE THAN 2 DAYS STRAIGHT. IT STARTS WITH THE RADIO SHUTTING OFF WHILE DRIVING. NEXT THE WIPERS WILL NOT WORK THEN THE POWER WINDOWS WONT OPEN. EACH TIME HE GETS IN AND OUT OF HIS CAR, ANOTHER ELECTRICAL FEATURE WILL NOT WORK. FINALLY, WHEN HE GETS IN TO START HIS CAR AND IT WON'T TURN OVER. IN APRIL 2009, HE HAS THE ELECTRICAL SENSOR IN THE GEM MODEL REPLACED. ON APRIL 28TH 2010, HE HAD TO HAVE THE MULTIFUNCTIONAL FUSE BOX REPLACED. IN MARCH 2011, HE HAD A NEW BATTERY INSTALLED. TODAY HE IS WAITING FOR AAA TO JUMP HIS CAR AS IT WON'T START. I CALLED THE DEALER WHO INFORMED ME THAT THEIR ARE NO KNOWN RECALLS FOR THIS ISSUE. WE WERE TOLD BY ANOTHER DEALER THAT IT SOUNDS LIKE WATER IS GETTING INTO THE FUSE BOX MODULE DUE TO THE FRONT WINDOW NOT BEING PROPERLY SEALED . *TR

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE PARKED AND UNOCCUPIED, THE VEHICLE IGNITED IN FLAMES. THE FIRE STARTED UNDER THE HOOD FROM THE DRIVER SIDE. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT THERE WAS AN UNKNOWN RECALL THAT COULD HAVE BEEN ASSOCIATED WITH THE FAILURE. THE CONTACT STATED THAT THE CAUSE OF THE FIRE WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 175,000.

2002 FORD F-150. CONSUMER STATES A MAJOR WIRE HARNESS BURNED ON THE R.H. EXHAUST MANIFOLD AND THE PROTECTIVE PLASTIC SLEEVE WAS GONE AS WELL AS THE INSULATION. *TGW THE CONSUMER STATED THE CHECK ENGINE LIGHT ILLUMINATED AND THE OVERDRIVE LIGHT STARTED FLASHING AND IT WOULDN'T SHIFT PAST 2ND GEAR. *JB UPDATED 06/07/11

TL*THE CONTACT OWNS A 2002 FORD F150. THE VEHICLE WAS SITTING OVERNIGHT AND THE HORN STARTED TO HONK AS THE VEHICLE WAS ON FIRE. THE FIRE STARTED INSIDE THE CAB OF THE VEHICLE AND IT WAS TOTALLY DESTROYED. THE FIRE DEPARTMENT WAS CALLED AND A REPORT WAS FILED. THE FIRE DEPARTMENT DOES NOT KNOW THE ORIGIN OF THE FIRE. THERE WERE NO INJURIES. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS CALLED AND STATED THAT THEY NEEDED TO CHECK THE FIRE DEPARTMENTS REPORT. THEY OFFERED NO OTHER ASSISTANCE. THE FAILURE MILEAGE WAS 80,000.

SPARK PLUG BLOWING OUT HEAD. DAMAGING HEAD, COIL PACK AND INJECTOR LINE. *TR

I HAVE A 2002 FORD F150 WITH THE 4.6L V8. THE TRUCK HAS 109,000 MILES. NUMBER 4 PLUG EJECTED ON NOVEMBER 11TH WITHOUT ANY SERIOUS DAMAGE. I REPLACED THE PLUG AND COIL. I WAS DRIVING HOME ON DECEMBER 23RD THIS TIME THE PLUG EJECTED AND HIT THE UNDER SIDE OF THE HOOD AND SOUNDED LIKE A BOMB WENT OFF. I DID SOME RESEARCH ON THE INTERNET AND FOUND THIS IS A WIDE SPREAD SERIOUS PROBLEM WITH THE FORD TRITON ENGINES. I ALSO DISCOVERED THAT FORD WILL NOT COVER THE COST OF THE REPAIR. IF I HAVE THE DEALER REPAIR THE PROBLEM THEY WILL ONLY REPAIR THE ONE PLUG. SO I WILL PURCHASE A REPAIR KIT AND REPAIR ALL THE PLUGS MYSELF. THIS SEEMS TO BE A DESIGN PROBLEM THAT SHOULD BE COVERED BY FORD. *TR

I GOT INTO MY 2002 FORD F150 ONE MORNING, CRANKED IT AND WENT TO PUT IT IN DRIVE AND IT WOULD NOT.ALSO MY INTERIOR LIGHTS WOULD NOT WORK. AFTER DOING RESEARCH I FOUND OUT IT COULD POSSIBLY BE A FUSE. I CHANGED THE FUSE AND IT WORKED., ABOUT A MONTH LATER IT DID IT AGAIN SO I CHANGED THE FUSE AGAIN, THAT ALSO WORKED AGAIN. IN THE MEAN TIME I ALSO HAD PROBLEMS WITH MY BRAKES, WHICH I HAD JUST CHANGED. AFTER ABOUT A MONTH WITH NO PROBLEMS WITH MY FUSES, I TOOK MY TRUCK OUT OF TOWN FOR FOUR DAYS. WHEN I GOT BACK I HAD TO GO STRAIGHT TO WORK, APPROXIMATELY 3:00 PM. AT THE FIRE STATION I WORK AT. AT 11:45PM DISPATCH WOKE ME UP OUT OF THE BUNKROOM TO INFORM ME MY TRUCK WAS ON FIRE. *TR

OUR 02 FORD F150 CAUGHT FIRE IN OUR DRIVEWAY WHILE WE WERE NOT HOME AND WAS DESTROYED. THIS WAS 3 DAYS AFTER BEING OPERATED. THE FIRE WAS LOCATED ABOVE THE FRONT DRIVER SIDE TIRE AT THE BRAKE FLUID RESERVOIR. OUR NEIGHBOR SAW FIRE AND WAS ABLE TO SAVE OUR BOAT AND HOME BY COMBATING THE FLAMES WHILE WAITING FOR 911 TO RESPOND. OUR INSURANCE COMPANY CALLED IT A TOTAL LOSS. WE CALLED FORD TO SEE IF OUR VIN NUMBER HAD RECALLS, AND THEY SAID YES, FOR THE CRUISE CONTROL MODULE. WE NEVER RECEIVED NOTICE FROM FORD REGARDING A RECALL!!! WE HAVE NOT HAD ANY PROBLEMS WITH THIS VEHICLE UP TO THIS POINT. THE FIRE CHIEF SAID THAT IF MY NEIGHBOR WOULD NOT HAVE SEEN THE FIRE WE WOULD HAVE LOST EVERYTHING. *TR

2002 FORD F150. 4X4. 5.4 L V8. DRIVERS SIDE LEAKY WINDSHIELD. LEAK CAUSES CORROSION OF ELECTRICAL COMPONENTS UNDER DASH. THE GEM MODULE; WHICH CONTROLS MOST ALL ELECTRONICS ON THE DASH; RADION, 4X4, WIPERS, HEADLIGHTS CONTROLS, HEATING AND AIR CONDITIONING CONTROLS. DUE TO THE CORROSION OR THE GEM MODULE AND FUSE BOX ON DRIVERS SIDE OF VEHICLE THE STARTER WILL RANDOMLY ENGAGE ITSELF AS WELL. MANY OF THE RELAYS UNDER THE DASH ARE UNDER ABNORMAL CONDITIONS. DURING THE MALFUNCTION OF THE ABOVE TWO ITEMS THE RELAYS WILL "CHATTER" CONSTANTLY. ALL OF THE ABOVE CONDITIONS WILL HAPPEN WITH THE KEYS OUT OF THE IGNITION. WITH NO KEYS IN THE IGNITION THE FAN BLOWER WILL STILL RUN, HEADLIGHTS STAY ON ( IN AUTO POSITION). NUMEROUS OTHER ELECTRICAL PROBLEMS. THERE ARE NUMEROUS POSTINGS OR IDENTICAL TROUBLES ON THE INTERNET. COUNTLESS FORD MECHANICS WILL TELL OF SAME TROUBLES. *TW