Ford Super Duty (1999-2016) :: F350 - Randomly Clicking Relays And Battery Running Down


May 5, 2017

Bottom-line question: is there a way to tell if a GEM is fried?

'99 F350 with a known water leak (not where it leaks, but for sure that it does--glove box, floor mats, etc.).

Recently started running the battery down, and then noticed that under low-voltage conditions it would click the door-lock relay back and forth, etc.

Now, after several inches more rain, it's making clicking and other electrical havoc noises any time it's not running, key in or out, even when the battery is up enough to start the truck (V10). I charged the truck and started it, drove it around to let it charge some more, and when I got home and shut it off, it was clicking as bad as ever.

After reading on the forums a while, I went ahead and pulled the fuse panel and GEM. The two big fuse panel connectors were definitely wet inside, and there's a little corrosion on one or two of the bayonet connectors. The GEM itself doesn't seem wet, and it doesn't look/smell like I've let the smoke out of it.

What do I do at this point? Last time, after I charged it up, it seemed to hold a charge and didn't do any clicking. I thought at the time it was related to the door switches that had been on the fritz (and which I lubricated after reading about where they are). Now, I suspect it was just because it had been long enough since it was rained on that things had dried out.

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Ford Super Duty (1999-2016) :: PCM Or ICM Relays Clicking After Staring And During Idle

The truck runs but After staring and during idle there is a heavy relay click and the speedo jumps to 20 or 30 mph. Afterwards on a 30 to 45 sec cycle there is a relay clicking in the area of the PCM relay.

Speedo jumps to 10mph and radio resets. 15 to 20 seconds later there is a light click behind the dash ( no speedo jump or radio reset). Rinse and repeat...

I have tried to locate which relay is setting it is either the PCm or possibly the pcm and the icm. Can't tell. Popped and swapped for s&@$s and giggles but no change.

1999 7.3, 308,000 miles. No mods. Original injectors and no other major repairs.

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The battery light is on when running. The light is dim at idle. Light is bright when driving with rpm's. The battery voltage is 12.8 per my older volt gauge. Alternator out put is 14 volts at idle and with rpm (2,000) +. I had the Alternator checked at AutoZone in there parking lot. Meter hooked up. The alternator passed all test.

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At slow speeds turning hard or 15-20 taking a turn, it sounds like a ratchet clicking from somewhere on the left side, right around the drivers door, from what I can hear from the cab. Does it in 2wd, 4wd hi/low, hubs locked or not. I changed the vacuum pump, no leaks, changed the IWE solenoid, pulled out both locking mechanisms, tightened crossmember, checked everything from the hours of research I did on the internet. I cannot find the problem. I don't know what else to check. Front axles free spin and lock when they are supposed to. I'm at the end...

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I then put in a new starter relay. Still having the same issue. I believe I have a short because I tested for it but am unable to locate the short. I heard if you over work the bushings in the starter they can ground out on the casing which will cause something similar to this to happen. I work in ND and had to cold start it in - temperatures the morning this all began. I purchased a new starter but don't want to put it in if that is not the issue.

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