Electric Fan Conversion Complete! (Parts list included)
Sept 5, 2017 19:54:00 GMT -5
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Post by vr4madness on Sept 5, 2017 19:54:00 GMT -5
I conducted tons of research, collected the parts, and finally was able to perform the task. I didn't really know exactly what I was doing, so this was a bit of a task for me. It took me about 6 hours to do everything, though if you are experienced, you could probably do it faster than me. The good news is that with everything, you are looking at about $270-$300 for all the parts. That seemed pretty cheap to me. I am a little bit in a hurry so I may not finish the write up right now. If you have questions feel free to ask! Oh and it has worked great so far, I climbed a hill that normally causes temperatures to rise a little, and it stayed well within cool temperatures. I still have yet to test it on a serious off road situation.
I replaced my radiator, that is optional of course, but I figured that since I was in there, I might as well replace what looks to be the original radiator (130,000 miles). I bought a Ford Contour fan (3400 CFM) which fits perfectly over the stock radiator. I used 1/2" weather stripping tape and applied it to the radiator where the Ford Contour fan shroud would touch the radiator. I didn't want the shroud the rub against the radiator so this was my solution which also helps to create seal allowing the fans to pull more air through the radiator. You will can cut the extra mounting tabs off the Ford Contour fan shroud if you want, I did because I like things to look good and there was no reason to have the tabs sticking out in the way. I used the the stock MS shroud bolts and mount locations for my custom mounted brackets. As you can see in the picture, I just drilled my own holes and used the M-6 bolts and nuts to mount the brackets I made to the shroud.
I bypassed the resistor on the Ford Contour fan and just linked the two fans to turn on together at the same time. The thermostatic fan controller came with its own built in relay that can only handle 30 amps which isn't enough for this fan setup. Ford requires a 60 amp fuse to handle this fan so I built the system to handle more than 60 amps. That is where the other relay came in, which can handle 80 amps. There there is also a 60 amp fuse between the battery and the main relay. I also wired in the power to thermostatic fan controller (yellow wire) to the wiper blade motor harness (blue wire) which is activated via the ignition. That allows the fans to turn off with the truck. If you run the power to the battery, the fans will continue to run until the heat drops below the the threshold that you set for it. I set mine up to turn on when the water pump comes on.
Parts You Will Need:
• 2- Ford Wire Harness Connector Radiator Cooling Contour
o www.amazon.com/gp/product/B0040D0MCE/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
• Dewhel Aluminum Black Water Temp Meter Temperature Gauge Joint Pipe Radiator Sensor Adaptor Clamps 38mm
o www.amazon.com/gp/product/B018FY12CW/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
• TEMCo 12 V 60/80 Amp Bosch Style S Relay with Harness Socket Automotive 2 YEAR WARRANTY
o www.amazon.com/gp/product/B00QW3O4QU/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
• Hayden Automotive 3651 Adjustable Thermostatic Fan Control
o www.amazon.com/gp/product/B000C39C72/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
• MWGears CN-023 8 Gauge (8-AWG) Copper Crimp Ring Terminals, 4-Pack
o www.amazon.com/gp/product/B01MRBMHLU/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
• Denso 221-3300 Radiator
o www.amazon.com/gp/product/B0049GEA34/ref=oh_aui_detailpage_o06_s01?ie=UTF8&psc=1
• Jex Electronics In-Line Car MAXI Blade Fuse Holder Waterproof 8AWG Upto 70A 12V/24V/32V DC
o www.amazon.com/gp/product/B01AKDHXXS/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1
• TYC 620750 Ford/Mercury Replacement Radiator/Condenser Cooling Fan Assembly
o www.amazon.com/gp/product/B000IYPSEQ/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1
• ½” M-6 Metric Bolts (x4)
• M-6 Metric Nuts (x4)
• Washer (x8)
• Crush Washer (x4)
• ½” Weather stripping (tape)
• Aluminum Bar 1/8” x 1”
• 6’ of red and black wire (8g to 10g)
I replaced my radiator, that is optional of course, but I figured that since I was in there, I might as well replace what looks to be the original radiator (130,000 miles). I bought a Ford Contour fan (3400 CFM) which fits perfectly over the stock radiator. I used 1/2" weather stripping tape and applied it to the radiator where the Ford Contour fan shroud would touch the radiator. I didn't want the shroud the rub against the radiator so this was my solution which also helps to create seal allowing the fans to pull more air through the radiator. You will can cut the extra mounting tabs off the Ford Contour fan shroud if you want, I did because I like things to look good and there was no reason to have the tabs sticking out in the way. I used the the stock MS shroud bolts and mount locations for my custom mounted brackets. As you can see in the picture, I just drilled my own holes and used the M-6 bolts and nuts to mount the brackets I made to the shroud.
I bypassed the resistor on the Ford Contour fan and just linked the two fans to turn on together at the same time. The thermostatic fan controller came with its own built in relay that can only handle 30 amps which isn't enough for this fan setup. Ford requires a 60 amp fuse to handle this fan so I built the system to handle more than 60 amps. That is where the other relay came in, which can handle 80 amps. There there is also a 60 amp fuse between the battery and the main relay. I also wired in the power to thermostatic fan controller (yellow wire) to the wiper blade motor harness (blue wire) which is activated via the ignition. That allows the fans to turn off with the truck. If you run the power to the battery, the fans will continue to run until the heat drops below the the threshold that you set for it. I set mine up to turn on when the water pump comes on.
Parts You Will Need:
• 2- Ford Wire Harness Connector Radiator Cooling Contour
o www.amazon.com/gp/product/B0040D0MCE/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
• Dewhel Aluminum Black Water Temp Meter Temperature Gauge Joint Pipe Radiator Sensor Adaptor Clamps 38mm
o www.amazon.com/gp/product/B018FY12CW/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
• TEMCo 12 V 60/80 Amp Bosch Style S Relay with Harness Socket Automotive 2 YEAR WARRANTY
o www.amazon.com/gp/product/B00QW3O4QU/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
• Hayden Automotive 3651 Adjustable Thermostatic Fan Control
o www.amazon.com/gp/product/B000C39C72/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
• MWGears CN-023 8 Gauge (8-AWG) Copper Crimp Ring Terminals, 4-Pack
o www.amazon.com/gp/product/B01MRBMHLU/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
• Denso 221-3300 Radiator
o www.amazon.com/gp/product/B0049GEA34/ref=oh_aui_detailpage_o06_s01?ie=UTF8&psc=1
• Jex Electronics In-Line Car MAXI Blade Fuse Holder Waterproof 8AWG Upto 70A 12V/24V/32V DC
o www.amazon.com/gp/product/B01AKDHXXS/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1
• TYC 620750 Ford/Mercury Replacement Radiator/Condenser Cooling Fan Assembly
o www.amazon.com/gp/product/B000IYPSEQ/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1
• ½” M-6 Metric Bolts (x4)
• M-6 Metric Nuts (x4)
• Washer (x8)
• Crush Washer (x4)
• ½” Weather stripping (tape)
• Aluminum Bar 1/8” x 1”
• 6’ of red and black wire (8g to 10g)