-Electric Fan Install
The Ford Taurus Electric Fan

Using an electric fan offers superior cooling ability vs the stock fan, and you receieve some horsepower and gas mileage gains by removing that parasitic clunker.

It was my understanding that the electric fan from any 1990-1995 V6 3.8L Ford Taurus will work. I found mine at a nearby salvage yard from a '95 Taurus, $20. The Taurus electric fan pulls an impressive amount of air, 2500 CFM on low and 4500 CFM on high. The high easily surpassing the stock fan.

After removing the old fan shroud from the Jeep, I had to loosen up and remove the four bolts that held on the mechanical fan. I replaced the old bolts using fine threaded 5/16" x 1/2" bolts and a lock washer. Doing this allows more clearance for the fan to fit.

 

I had to trim the electric fan shroud about 1/2-5/8" on all sides for a snug fit. It also needs to be flipped 180° to offset it from the water pump. I marked the new top with a "T" so I would not get confused. This new shroud is not a direct bolt in, in fact I had to cut off its original mounting holes. Although it is not a direct bolt in, it does fit very nicely onto the radiator fins and it also covers a large vertical area as well.

To secure the new shroud, I made some real simple metal tabs using 1/2" x 1 3/4" flat stock cut to 3 1/4" lengths. The holes were drilled just big enough to use the orignal bolts that held the old fan shroud in place. I then drilled the same size holes into that shroud that match up with the holes in the tabs. Before I tightened the new fan/shroud into place I put some thick felt material on all four corners of the shroud to be sandwiched in between the shroud and the radiator fins. This is to help prevent rubbing between the two.

 

The electric fan should not be running all the time, it needs a way to turn on and off based on the temperature of the cooling system. That is where buying a thermostatic fan control comes in handy. This controller has a temperature probe that goes into the top radiator hose. The temp probe has a wire that goes to a control unit that has variable temperature settings. When the set temperature is reached, an electrical connection is made and the fan kicks on. This reasonably priced controller made by Hayden Automotive is highly recommended throughout the Jeeper community, so it is the one that I chose to use. Although it looks complicated, the wiring is pretty straight forward:
Battery > Fusible Link > Relay Solenoid(turns on when ignition is on) > thermostatic controller > fan.
I originally used a standard 50amp automotive relay. The problem is that when the electric fan is on high, it pulls 90amps at startup then a continuous 50amps at speed. Over time the relay began to get hot and melt on one of the sides, as seen in the picture below. To fix this I replaced the standard relay with a solenoid rated at 80amps continuous load. I discovered that these solenoids, such as this one, are much cheaper to buy online than at a local autoparts store.

My original setup. The mounted thermostatic controller and relay. Notice the right side of the relay has started to melt   My new setup. Added a solenoid for HIGH speed and the relay became LOW speed
Ford Taurus electric fan wiring schematic

There are NUMEROUS ways to approach wiring this unit together. I have looked at lots of wiring schematics that are on the internet, and ultimatley this is the way I came up with that best suited my particular needs.

The fan will only run if the ignition is on. The fan is triggered by the thermostat controller. Inside the Jeep I have a switch that toggles the fan between HIGH and LOW speed. A manual overide switch that cuts the fan off no matter what, incase of a water crossing and such. I do not have a working A/C unit, if I did I would have left LOW the default speed and wired the HIGH solenoid into the A/C compressor so that when the A/C is used the high speed is activated.


The Results

Removing that heavy clunker of a fan has done more good than I possibly could have imagined. The Jeep actually starts easier now. There is a signifcant difference in acceleration in 1st-3rd gear, and I have gained 1.25mpg highway. The fans LOW speed has easily kept the engine cool in typical driving situations. Overall, this modification was well worth the time and effort. Highly recomended.