Summary: Water leaked around the left side of windshield causing electrical failures, including but not limited to the starter, radio, windshield wipers, headlamps, etc. The water entering the vehicle wet the power distribution box (pdb) and the generic electronic module (GEM). These components control various electrical systems in the vehicle. The vehicle continued to attempt to start itself without any key in ignition until it resulted in the starter burning up as well as damaging associated wiring and battery. Vehicle's windshield had to be replaced as was the starter, associated wiring and battery after vehicle was towed to repair facility.

- Cherry Hill, NJ, USA

There is a defect with the installation of the windshield that causes water in enter the cab. Upon entry, the water goes into the GEM mod and fuse panel of the SUV. This shorts the system - at one point you may encounter the heater turning on without the key in the ignition. Here is a special notice sent by Ford in 2002 regarding this problem: *Ford special message #15773 variouselectricalconditions resulting from water intrusion into the GEM/cjb some 1997-2002 Expedition and 1998-2002 Navigator vehicles may exhibit various unusual electrical conditions, including but not limited to: Xxxxx xxxxx rear blower or eatc staying on with key out of the ignition, radio staying on after doors opened and key out of ignition, wiper circuit failure codes, and multiple system warning lights with 'short to power' or 'low battery voltage' dtcs. These symptoms most often occur after a rain or snow. This may be due to GEM/cjb water intrusion resulting from a windshield water leak. To service, remove the GEM and cjb from thevehicle, separate them and inspect for water contamination or corrosion. If found in either component, replace both components and completely reseal the windshield. Effective date: 04/05/2002 Ford Motor Company

- Plano, TX, USA

Well first it was the horn that has been replaced several times and now all of the sudden cruise control doesn't work. I was annoyed about the horn, but now the cruise control... seems like something is wrong with that horn and cruise control set up.... and I was wondering about the paint because it is also pealing like crazy...

- Reno, NV, USA

The contact owns a 2000 Ford Expedition. The contact stated water was leaking into the vehicle from the front windshield, onto the instrument panel and into the computer system. The failure would cause the computer chips to malfunction and the vehicle would become inoperable. The vehicle was taken to the dealer seven times for the failure. The dealer replaced the damaged computer chips nine times before discovering the failure was caused by the leaking windshield. The windshield was not replaced. The manufacturer would not provide any assistance. The failure mileage was 30,000 and the current mileage was 98,000. Updated 11/24/10 updated 11/20/10

- Tampa, FL, USA

I have a 2000 eddie bauer Ford Expedition when it rains hard I have problems with my electrical system eg; motor runs when car is turned off, odometer comes on and off, 4X4 light flashes on and off... dealer informed me that the problems stems from a windshield leak, the leak has been repaired by a windshield professional, he then informed me that I need to replace my GEM module and fuse box. I'm concerned of possible fire. I only have one car my children lives might be in danger. Ford needs too take care of this problem. These are major defects that needs too be address. Ford Motor Company faulty or defective designs that has caused this leakage that's causing electrical problems to the GEM module and fuse box is putting not only me but other drivers in danger also.

- Suitland, MD, USA

Leak in windshield area. Shorts out he fuse box and GEM. Once this happens there are multiple electrical problems. Ford does not cover the cost for this obvious defect. Have heard and read of many other people with same issue. This can make the vehicle shut off while driving, windshield wipers to stop functioning, vehicle trying to start with know keys in it. It can effect all facets of the electrical system.

- Germantown, WI, USA

I own a Ford Expedition 2000. The paint of the car is letting go form the primer this vehicle has been taken care of. I checked on line and found several other people complaining about the same problem. The vehicle was inspected by a body shop and the stated that Ford should be responsible since it is the primer that is letting go of the metal and bubbling the paint right if the car. When the paint flakes off it is just the metal and no rust at that point then with in days it is rust please help.

- Coeur D Alene, ID, USA

Spare tire winch mount cable broke while driving on freeway. Cable sheared at top near the winch mount. Spare tire bounced and rolled into oncoming traffic at freeway speeds. Tire nearly hit several cars head on. No injuries or accidents. Repaired myself with replacement winch mount from Ford.

- Frostburg, MD, USA

Rain/snow cause water to leak into the GEM module & fuse box under driver's side dashboard causing complete electrical failure, wacky electrical things like fan motor running without key in ignition, strange "stupid lights" periodically on dash, etc. Have replaced these twice, very expensive.

- Franklin, TN, USA

I have a 2000 Ford Expedition, the windshield is leaking onto my GEM module and fusebox behind the dash and causing all kinds of electrical problems. The dealership has quoted me over $1000 to fix this problem, and I have read many forums and alot of complaints about this exact same problem all over the country. Sounds like this problem should be made into a recall. It is costing people lots of money to fix one of Ford screw-ups.

- Vale, NC, USA

I purchased a 2000 Ford Expedition eddie bauer SUV new from a local dealer in the los angeles area. Current mileage is 127,300. This concerns a very serious safety problem that has happened twice since we have owned this vehicle. This vehicle is only used to commute to work, never off-road or abused in any manner. A few months into our ownership, we were traveling on the freeway and going over a overpass at 60 miles an hour the spare tire dropped off the SUV and rolled across four lanes of traffic at night. Luckily, it did not kill someone. Then about 8 or 9 months ago it happened again just backing out of our driveway. Inspecting the problem it is clear the steel cable hoist holding the tire up under the rear is breaking under stress. It is clear this is a design defect and a very real safety issue. We have taken it to the local dealership and I have called their 800 number. They claim the vehicle is outside the warranty period. I say this is a safety issue that Ford should not only fix but should redesign the whole mounting system to better support the tire. The tire and rim should have a positive locking device that securely holds the tire in place so the steel cable hoist is used only to raise and lower the tire when the vehicle is at rest. Ford will not put this in writing. I have filed complaints on this issue here in California with the dmv and other agencies - they are referring me to mediation boards to settle it financially. But the Ford fix of installing another steel cable hoist system is not safe. I am considering a third party mounting system to the outside of the vehicle because I do not want this to happen again. Presently, I am driving without the spare tire because we do not want another Ford fix and it would be unsafe carrying it inside the vehicle. You are my last chance of resolving this safety issue. My next step will be to pursue this complaint directly with the public media. That is how serious I am taking this problem.

- Woodland Hills, CA, USA

My 2000 Ford Expedition has caused us numerous headaches and near accidents as a result of rain entering the vehicle due to a defective windshield installation. Once the rain water enters the driver side dash panel ( underside ) and comes in contact with electrical components mounted there, numerous failures occur, such as : windshield wipers quit working, interior and dash panel lights flash on and off, and eventually quit working. The safety switch which allows the vehicle to be placed in drive while depressing the brake also fails once the vehicle is turned off. These problems are not just a nuisance, but a safety hazard, and after speaking to other Expedition owners and reading numerous common stories of the same problem, I feel that this is a manufacturer's defect and should be recalled and repaired accordingly. In closing I would like to state that my wife was driving on a very busy interstate in the rain when she experienced our latest failure. Although there was no accident, it was definitely a close call, and could have been potentially fatal. We may not be so lucky the next time....

- San Antonio, TX, USA

Water is leaking in from the windshield according to the dealership. The water is then entering the vehicle and affecting the fuse box and the GEM module. It does very weird things to the electrical components of the vehicle, windshield wipers quit working while driving down the road, radio turns off once vehicle is put in drive, running lights do not work, battery dies, just to name a few the list goes on and the consequences are very dangerous in some cases. Have you ever been driving down interstate in the rain and then all of a sudden have no wipers. Let me tell you not good. The dealer wants an arm and a leg to fix it, money I do not have after spending 15K on a vehicle. So help me anything happens as a result of the failure and there will be a lawsuit. Take a look around on the internet and there are hundreds maybe thousands complaining about the same issue. Something must be done.

- Minster, OH, USA

Leak in driver side windshield which leaks into fuse box causing several electrical problems, engine revs on its own, starts by itself, windshields wipers turn on and off, radio works than turns off, head lights turn off while driving note have had it into dealership and repaired and it still doing the problems, was told by the tech it was a leak and they would not be able to guarantee the work. Happens every time it snows or rains heavily.

- Nixa, MO, USA

My 2000 Ford Expedition leaks from the windshield during heavy rains, and water comes into the cabin area. The water also has caused my GEM (general electronic module) to malfunction, making my HVAC blower to spontaneously turn on after I turn off the vehicle and remove the key from the ignition. This causes my battery to run down. I would expect that this kind of malfunction could lead to more serious problems and possible fires due to unwanted electrical activity.

- Missouri City, TX, USA

I have now replaced the front brakes and rotors 3 times since buying this 2000 Ford Expedition in late 2000. I was informed by a former service manager from Ford that this defect is known and wide spread. What he explained to me that they received a large lot of front right brake lines that were to small or concluded enough so as not to let the caliper completely release the pads from the rotor causing failure of both in as little as 15000 miles. There is a cover up and people are probably having accidents due to this defect. I will never buy another Ford. We also had the leaking windshield over the drivers side that would leak into the electrical boards in the dash causing the lights to go out/the radio to go off and on by itself. The worst was it trying to start with no key or person in the vehicle and ruining the starter and the battery. Do not buy this vehicle!!!!!!!!!!!!! because Ford still lies that these are not their problems.

- Archer, FL, USA

Rain leaked through the windshield of my 2000 Expedition causing damage to the electrical fuse box. My electrical system started acting whacky while driving. This was a distraction and could have resulted in a crash. Fixing the problem resulted in replacement of the windshield and fuse box/GEM module costing approximately $1000. I did a search and this seems to be common on the internet among Expedition owners within that range of year. I also noticed this is complaint # PE05033 on this sight.

- Santa Barbara, CA, USA

2000 Expedition heater blower had to be manually turned off after keys were removed from ignition. When attempted to start vehicle it would not start. The fuse box was rusted, corroded and full of water. This was the result of the windshield not being sealed properly.

- Richland Center, WI, USA

Windshield leaking water which blew out fuse box and GEM causing erratic behavior in windshield wipers, radio, heater, air conditioner, overdrive, transmission, speedometer, odometer, RPM gauge, and it also led to our PCM having to be replaced. Replaced windshield, fuse box, GEM, PCM. Cost us $1700 dollars. Two weeks later after a rainy night it is at the dealer again.

- Millington, MD, USA

Water leakage doing damage to the GEM module and junction box. Dealership advised me the leakage was from the windshield area. Vehicle has a "new" windsheld and the damaged area had "old" rusty damage. Both electronic items were replaced at the expense of $730.11 (Ford dealership).

- Winchester, CA, USA