When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
I have had it with two annoying festering problems after my rebuild - one of which the car would overheat with AC on driving around town in hot weather. I decided to get it right once and for all.
Even though I had new parts, I replaced the thermostat with a high flow design and tested it. I then had the radiator checked and back flushed. Last was the sloppy stock fan setup.
I tried to source a mid-90's Taurus fan but couldn't find one so I bought the Dorman replacement. I learned that although the cheap Chinese stuff fits and works like an OEM fan, they do not blow like an OEM- they are weak. Needless to say that fan is going back as it really did not improve things at all.
I had also read about the Ford/Volvo double fans by Bosch for Ford OEM on the late 90's Windstar 3.8L vans. Monstrous air flow, amperage, and size. I did some careful research and it looked like those might might barely fit into a thirdgen.
As luck would have it, the local pick-a-part had a recently added 3.8L Windstar and I swung in I removed the fan setup easily. I was pissed that the yard wanted $67 for the fan setup (OEM from Ford is $250). RockAuto had a "VDO" branded one, new for $87. Initially, I got mad and and left the fan there, then I figured there was probably a big difference between OEM fans and cheap replacement products. So I swallowed my pride and went back and got it.
Long story short, I was able to barely fit it in and onto the radiator. I must've test-fit the assembly 20 times before I got it locked in and even at that, it's a shoe-horn fit. It now drops in easily but access to the lower hose is going to have to be from underneath. I also had to really futz with the power steering cooling lines.
The hero of this project is my little Milwuakee 12V dremel with the universal cutting bit. Plastic shroud shavings EVERYWHERE. But after about six hours, it was mounted to the radiator and drops right in. I made sure to seal around the shroud all the way around. The wiring to each motor is #10 or bigger with soldered connections and a big 70 amp Volvo dual speed fan relay. Instead of dual speeds, I am going to use it to sequentially turn on the fans.
It's not done yet but I will report back when I am. I sure hope this works. I half expect the fans to bend the radiator from the sucking force. I've attached a video as well.
That looks pretty good. I have the OEM Taurus fan on mine. It moves a ton of air but the shroud is almost non existent. Your's is far more sealed than mine.
Sealing the shroud is super important. Just go to Home Depot and get a roll or two of weatherstrip. Thicker the better.
The deeper fan clears the power steering pump easily. It isn’t close. The big challenge was sealing the shroud around the radiator. The fans barely fit between the coolant inlet and outlets. But they do. Also, the steering box gets close to the fan but it clears it. If I have another crack at it I could probably get it a bit better but I am pretty happy with it.
The lower hose was not an issue. I attached it to the radiator first and then dropped the assembly in. Plenty of room to attach to the water pump.
These things move a ton of air and the sealed shroud forces it through the radiator. Easily pulls and holds cardboard on the other side of radiator and takes some effort to pull it off. Took the car out for a drive. Beat on it with the AC on and stayed just fine. Was not hot so I will have to see but I am hopeful. I’ll put up some pics of the installed fans when I get a chance. Each fan is on its own 30A fuse and relay. I couldn’t reuse the Volvo two speed relay.
Last edited by Tootie Pang; 07-27-2020 at 09:44 AM.
FINALLY got around to testing this setup in the heat. 97 degrees, full air conditioning, stop and go, climbing hills. Engine temp never got above the midline, 220. AC stayed nice and cool, coolant exiting the radiator was 180.
Just as an FYI Derale makes a nice fan shroud setup, I just took out my old 3 row Champion radiator and put in a new 2 row from them. Fans are 12" and pull 2000cfm ea
07-20-2020, 12:39 PM
