2002 Ford F-150: headlights failing or too dim

Filed Dec 24, 2016 · Electrical · 162,473 miles · TX

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/

Filed Feb 7, 2010 · Electrical · 105,000 miles · IN

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.

Filed Apr 12, 2005 · Electrical, Lights · 40,000 miles · OH · fire

I purchased my 2002 ford f150 super crew in august of 2002. I have had ongoing problems since I purchased the vehicle, and have had no responses or assistance from any ford dealerships. The problems started out with my radio going on and off all on its own. I took my vehicle to the dealership at least 10 times alone for this problem. Never any assistance. The problems escalated around 40,000 miles and my whole electrical system seemed to be shorting out. I have had fire under the dash, the headlights not work, the wipers would only work when the vehicle was in park, same thing with the heater, it would not turn off after you shut the vehicle off. Now this week I had another fire which I was able to put out on my own. I took it to a different dealer and they identified the problem with the gem module and central junction box. Apparently the vehicle was not put together correctly and these modules keep shorting out causing my vehicles problems. I have to wonder everyday whether or not my vehicle is going to catch fire and burn up. On a daily basis I can smell smoke coming from under the dash almost like burning plastic or wiring. None of the problems have been addressed and seem to be escalating. To me this is a safety issue. I would hate to think that I would be traveling with my family and the car catch fire while we are driving. The electrical system needs to be investigated and repaired. None of which has been done by the dealer I purchased the vehicle from. I even filed a complaint with the ford motor company and received no real concern.

Filed Jul 24, 2004 · Lights · 38,000 miles · CA

The 2002 ford f-150 headlight switch breaks upon turning on headlights. It has not caused me to wreck, however it is a problem with turning lights on at night, fog, or rain. This is the third time this has happened. I ordered it from perry ford of poway california, but the headlight switch is on back order. That is telling me that alot of people not just my self, are having the same problem. This should be a safety recall.

Filed May 13, 2004 · Electrical, Visibility · 53,379 miles · MI

Windshield seal leaked (rain) along roofline causing multiple electrical problems. Vehicle has multiple system warning lights visible on dash. Short circuit sounds coming from behind dashboard. Warning lights, blower motor and head lights operate without key in the ignition causing battery to be drained. Wipers cut off without warning. Door windows stop working without warning. Vehicle shifts into four-wheel drive without warning. Engine races while parked (revs to 4000 RPM and returns to normal). Sales man informed that ford will not cover the problem because the truck is out of warranty and to bring truck to dealer (5/3/04). Truck would not start until 5/8/04. Seal to windshield separated from vehicle on left side while driving to dealership (5/10/04). The truck now has excessive wind noise. Truck will no longer start (5/11/04). I called fords customer and requested that a representative from ford inspect the truck. Customer service asked that the truck be towed to a ford dealer. Truck was towed to local dealer. Dealer did not want to help me contact ford after I informed them that the truck has a defective windshield seal. Dealership informs me on 5/13/04 that the zone supervisor from ford said that there was nothing that could be done about the problem. In addition, dealer refuses to put statement in writing. The dealer also informed me that for a fee, they could seal the windshield and diagnosis the problem but the dealership where the truck was purchased from should do the repairs.

Filed Jan 30, 2004 · Lights · 20,000 miles · TX

While driving at any speed headlights, hazard lights, and turn signals did not work. Vehicle was taken to the dealer, who determined that another multi-function switch was needed. This will be the second switch to be installed.

Filed Sep 30, 2003 · Engine, Lights · OH

I have a 2002 ford f150 that has headlights going off while driving. I have had it repaired only for it to reoccur. This is not a minor problem to me and the dealership that I purchased it from is unable to make a service appointment for a week. I have another vehicle but not everyone has that privelege and I have decided to service it at another location. Maybe my vehicle is the only one and it is just something that happened. But I am concerned for my safety. Thank you for allowing me to voice my concern. Llc

Filed Sep 15, 2003 · Electrical · TX

Electrical system fails intermittently, causing headlights and other electronic components to blink.

Filed Aug 5, 2003 · Lights · 37,204 miles · FL · crash

I own a 2002 ford f-150, xlt, purchased on may 2002.returning from a trip to orlando florida, I was traveling westbound on I-10, 45 miles east of tallahassee when I lost headlights ilumination. Loss headlights caused me to run off the road, though I was able to keep control of vehicle and minimize material damages. Upon inspection, it was determined that headlight control knob in dashboard had became loose and had caused the headlights to turn off.

Filed Feb 14, 2002 · Lights · NC

While driving in the dark, darshboard lights and headlights will turn off at the same time without a prior warning for about thirty seconds. Dealer was contacted, but they could not find what was causing the problem. *ak