Ford Taurus Fan Install

[Tom Schenk]

This is an easy upgrade for a broken fan clutch. Here are the pics, and as always, feel free to contact me for more information.
http://community.webshots.com/album/225505072ewrkoF
-Tom

[Tom Schenk]

Since posting this I have made several changes to the original set-up. Rather then post the changes I'm just going to post a new write-up.:)

Preface: The OEM fan on my 1997 4.0L TJ failed. I decided to replace it with a Ford Taurus two-speed electric fan.

Parts list:
-Taurus fan: U-pull it for $25. Comes only off the 3.8L engine and has 3 wires.
-(2) fan relays: 1 from the donor car, another from the car next to it, or Napa.
-50 amp fuse: from donor car or Napa.
-(4) 5/16" x 1/2" Grade 5, fine thread bolts
-Hayden thermostatic switch: found @ Autozone with aftermarket electric fans. Lots to choose from; select according to needs and budget.
-Rubber door trim
-10 gauge wire, connectors, heat-shrink, tape, loom, etc...
___________________________
If you want to be able to turn the fan off/on manually from the cab, add:
-dash switch
-red, blinking 12v LED and holder
-SPST mini relay for LED
-16 gauge hook-up wire

Before you start. This fan draws alot of amperage. Use only 10G wire, high-amp relays (Ford OEM), and consider a high amp alternator (http://www.bc4x4.com/tech/2004/jeepalt/)
How you wire your relays is up to you. Here's how I did mine. (http://www.virtualjeepclub.com/showthread.php?t=11993)

Lets start. First, remove belt (not yours, the Jeep's :rolleyes: ). Remove the fan from the 4 studs on the water pump and remove the shroud. Remove the studs from the water pump. Bolt the pulley back on to the water pump using the 5/16" fine thread bolts. Re-install belt.

Next thing to do is cut the coolant overflow bottle mount off of the Jeep fan shroud. Set it aside for later. Using a Dremel or similar, trim the Taurus fan shroud to fit your Jeep's radiator. Finish the cut edges with the rubber door trim to keep your radiator fins safe and intact. Fab brackets to mount the fan. DO NOT USE THROUGH-CORE MOUNTS. THEY SUCK AND WILL DAMAGE YOUR RADIATOR OVER TIME. I used 1/8" angle and flat stock to make a Z shaped bracket. Use the coolant overflow mount as a template to mark the mounting holes. Install fan and mount the coolant overflow mount over your fan bracket.
http://www.photodump.com/direct/tomschenk/Picture012.jpg
http://www.photodump.com/direct/tomschenk/faninstall003.jpg
http://www.photodump.com/direct/tomschenk/Picture013.jpg


Now on to wiring.

Here is the wiring diagram:
http://www.photodump.com/direct/tomschenk/fanwiringdaigram.jpg

The 2 relays are Ford Taurus OEM fan relays. The 87A contacts are normally closed. When the Jeep's ignition is switched on, relay #1 is energized and sends power to the 87 contact and on to relay #2. Relay #2 then sends that power to the 87A contact and on to the fan low speed. When the thermostatic switch is activated it will switch the second relay to the 87 contact activating the fan high speed. It important that the high and low speeds do not receive power at the same time. They use seperate armatures. Power to both will result in premature fan death.

To wire the manual on/off switch, we need to add a wire in between the Jeep's switched power wire and the #1 relay. As a safety, I also added a blinking LED to remind me that the fan is off. The LED is wired to the normally closed 87A contact on the #1 relay. Use the mini relay to cut power to the LED when the Jeep is off, otherwise it will blink when the Jeep is off.

I mounted my LED in the gauge cluster:
http://www.photodump.com/direct/tomschenk/faninstall007.jpg

[FrenchChili]

Is it possible just to use an LED switch? They look cool.

Nice write up, Chris (My1stJeep) was actually talking about taurus fans today @ lunch

[Tom Schenk]

Like a switch that would light up if the fan was off? Sure, why not.

[DREDnot]

For a better fitting fan assembly, try one out of the 05-06 2.4L TJ. Its a bit more money but it bolts up to the factory shroud location and no gaps or airflow loss. It also has the mount for the overflow bottle:D

http://img355.imageshack.us/img355/9908/dscn5870r8wu.jpg

http://img293.imageshack.us/img293/1646/dscn00456tw.jpg

[Tom Schenk]

Will you sell me yours for $25 then? :D

[jeepnut7261]

Have you run this setup only this winter? What does the guage indicate?
I know the after market electric fans do not seem to be effective during an Arizona summer (tried the Flexilite fan myself, bummer!) Did not move enough air.
Good write up, I look forward to seeing how it works out!

[Tom Schenk]

This will be it's 2nd summer, no problems so far. The high speed rarely comes on, usually very hot days standing still. When off road I turn down the thermostat so it does not cycle back and forth so often and just stays on high. Engine temp does not ever exceed 210. This fan for sure moves air, over 2000 cfm. It has served me well; no complaints.:)

[AZMeN95yj]

Humm, great write-up, what are possibilities that this will fit a YJ. This could give my 4 banger a little more power.

[Tom Schenk]

Humm, great write-up, what are possibilities that this will fit a YJ. This could give my 4 banger a little more power.

It sure will, fit that is. Power, maybe not. But maybe another MPG. I'm getting around 20 city with my 4.0 on 33's.