It will have to wait till were out of our busy season. Right now Im booked solid for 3 weeks.
I did check the temp out of the ducts. 58 with the stock Jeep fan and bolted clutch and 42 with the Ford fan and clutch @ idle.
Wow, that's huge. If you look that up in the TJ FSM A/C pressure/temps chart that would seem to indicate an ambient change from the 110F range to the 90F range indicating something in the range of a 10F to 20F difference at the condensor.
You shouldn't need to change anything. The 4cyl Jeeps use the same Radiator as the 4.0 does. If your having problems with a 2.5 getting hot then you have a majorly plugged radiator, bad fan clutch etc.
Since you work at an A/C shop you could provide some cool facts for us.
Run both the stock fan setup and the Ford Explorer setup for 15 minutes each. Do it back to back so ambient temps are the same. Run the blower on high with the A/C on. Hook up your A/C system gauges and tell us what the high-side pressure is after the 15 minute tests. If the fan is pulling more air and cooling better then the pressure should drop showing that increased cooling.
Couple the pressure differences with a therometer reading stuck in the center duct would be very interesting.
There is a lot more to fans than just blade count. Pitch also plays a big role. It also depends on how far the pitch goes down the blade as the blade approaches the center or if the pitch is variable along the blade. The center is turning slower than the outside which creates turbulence or not depending on the pitch.
More blades and a curved tip are usually to decrease noise and more blades usually require more energy to spin them.
From the looks of the pics, it was a plastic fan. Or am I just seeing things. I didnt see anyone mention this earlier so maybe I am just seeing things.
'02 TJ Sport - 3.5" RE Springs/Mono-tubes; BFG A/T 33x12.50x15 on ProComp Black Steelies; JKS: BPE's, 1.25" BL, shock conversion, front Adj. TB's, quick discos, Extended Brake lines; FT 3-link rear; JCR 1-ton Steering; Warn 6" Flares; Olympic Slider Bumpers; OME SS; Taurus Electric Fan; 4.88 Gears; D30/D44 Detroit True-Trac Front/Rear;
Got er done! Took all of 5 minutes and didn't have to remove a thing. Seems to cool a little better, about 1 needle width lower on the temp gauge. I do have a 1" MML and no problems there. Can't say about AC as I'm still running without a top on. 105 still isn't hot enough.