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Old 03-25-2010, 02:05 PM
KSutherland KSutherland is offline
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Location: Greenwood, IN
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Vehicle: '02 Ram 1500 QC 5.9L
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Engine: 2002-2003 360ci (5.9L) Magnum V8 245hp 335lb/ft
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Step Five: Start Making the Mounting Brackets.
For mounting my electric fan, I used the holes already in the radiator. On the top and bottom rim of the radiator there are already some holes running across the length of the radiator. A 3/8 inch bolt fit in these holes perfectly and they match up in size to the holes on the length of garage door opener bracket that I bought. So I took some measurements and started cutting and bending metal. This can be done by hand because this metal is fairly easy to bend but I used a vise and hammer to make perfect 90 degree angles. I just think this makes the brackets look better but that is just for my personal preference, it is not necessary. I measured up and made the brackets for the top of the fan, I made two for the top, one on the passenger side and one on the driver’s side. The brackets I made bend over the front of the radiator, run across the top toward the driver’s compartment and down the back of the radiator to where the fan will go. This way I am able to use the holes in the front and back rim of the radiator to mount my brackets making them much more secure. I attached both of these mounting brackets to the radiator just loosely for the moment.

Step Six: Mark for Holes on the Fan Shroud of the Electric Fan.
The Taurus electric fan has a generous amount of shroud around it which makes it perfect for mounting in many custom applications. With the top two brackets attached loosely to the radiator I slid the fan into place. This fan fits into position on the radiator like it was made to go on there. With the fan in position on the radiator, I marked for the holes to mount the fan to the brackets. I used two bolts on each bracket (four total for the top two brackets) to attach the fan to the brackets. With the four holes marked I removed the fan and the brackets from the radiator. I then drilled the holes into the shroud around the e-fan and mounted the brackets to the fan.

Step Seven: Making a Bottom Bracket.
With the fan attached to the brackets I set the brackets back on the radiator and allowed them to hold the fan in place without installing the bolts because this whole setup is going to have to come back off one more time. Now with the fan being held in place with the top two brackets, crawl underneath the vehicle and measure for a bottom bracket. On my truck most of the holes in the bottom rim of the radiator are being used by trans cooler and other things. So I only had enough holes to mount one bracket to the radiator, but as strong as these brackets are, I doubt this will pose a problem. With the measurements taken, crawl out and make your last bracket. When it is done, take it under the truck, attach it to the radiator loosely and mark for where you are going to drill the last two mounting holes on the e-fan shroud. Now you can pull the whole assembly, drill your last two mounting holes in the e-fan shroud and attach the bottom bracket to the e-fan. At this point you should have all three brackets attached to the fan and you are ready for the install.

Step Eight: Install the Fan.
With all of your mounting brackets attached, place the fan and brackets back into place and tighten all of the bolts that attach the fan to the radiator. Do not over tighten it. It just needs to be snug as the fan weighs in at about 6 pounds and you have three brackets each made from metal rated to hold 50 pounds. Also, I used locking nuts for attaching everything just so it doesn’t rattle loose. Lock Tite will work well here too, just use something so your fan doesn’t come loose. I had read where some people have used weather stripping around the outside edge of the e-fan shroud to make a tight seal to the back of the radiator so I bought some. I never used it because this fan fits so well to the back of our radiator that there were no areas where air was sneaking out.

Step Nine: Reinstall Your Stock Shroud.
Just reverse the steps you used to remove the fan shroud earlier. I trimmed the bottom of my stock shroud to make it easier to get it to fit over the new fan but this is not necessary. I just did it because it was going to be close to slip the stock shroud over the new fan and I only wanted to do this one time. With the stock shroud back in place, replace your wiper fluid sensors and plugs, then reattach your coolant overflow bottle. At this point you are ready for some electrical fun J.

Step Ten: Wire Up the New Fan.
This step will be different depending on what type of controller you use, but I just followed the instructions that came with the controller I bought. The only thing that I changed is on the large gauge wires I used wire nuts instead of the supplied crimp style attachers. This is my personal preference because I have seen the crimp style come loose, but again this is just me and my personal preference. If you need a picture of the wiring schematic let me know, I have it in my garage.

Step Eleven: Run the Truck and See If Your Fan Works.
Well, this is the point of the payoff. I started the truck and let it run to get warmed up. While I waited I used this time to clean up my garage. When the truck got close to where I thought the fan should go on I attached my Superchips to the truck and started monitoring the coolant temp. When it reached the temp that I wanted the fan to turn on at, I adjusted my controller so that the fan would go on. And with that, my fan started running WHOOOO HOOOO! Now I let it run a little to see what would happen and sure enough the fan kept it right at the temp I set it the controller to keep it. Next I took the truck for a ride and the temp never moved from where I set it. With everything working the way I wanted it, I closed up shop and called it a day.
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