Ford Taurus 2 Speed Fan Install in a 1986 CJ-7 258ci I6
Taurus 3.8L 2 speed electric cooling fan (three wires)
Hayden-Imperial thermostatic switch
2 Ford Taurus fan relays (PN #FOAB-14B194-DC)
XJ/YJ/ZJ fuse & relay block
3 x 1/8 flat stock
10G & 16G wire
1 battery cable
Brian (last_renegade) wanted to put a Taurus fan in his CJ to replace its existing 12 puller. The 12" fan did great in NY but in AZ it was not cutting it. We eyeballed it and figured that it would be tight but would fit nevertheless.
The first thing was to trim the shroud down. This is pretty simple; use a square or other straight-edge and a Dremel tool to get the shroud edge flat and even. Note: We left the lip on the long side of the shroud.
Next was to fab the mounting brackets. WE DID NOT USE THE THROUGH-CORE MOUNTS. These may be fine for small, light fans but will destroy the radiator when used to secure a fan of this size. Using 2 stacked washers for spacing from the radiator, I welded a 3 wide strip on the driver side of the radiator. On the outside edge of that strip I welded 1 angle iron. On the other side of the radiator more 1 angle was welded. The lip we left on the long side of the shroud slips under the 3 stock and the other side drops in. The fan is then secured with #10 screws through the angle into the fan shroud sides.
Next we had to make room for this fan in front of the engine. I didnt get a picture of the stock setup, but the radiator mounting brackets mount on the engine side of the grill assembly. We had to move the mounts to the inside to get the clearance needed, kind of like an SOA for radiators, if you will. Brian notched out the top of the grill so the radiator can slide down to be mounted. Once the radiator was put in the notches were welded back shut.
Tight fit, eh? Thats about Ό between the pulley nuts and the fan.