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Ford Taurus Two Speed E-Fan Install (pics)

256K views 243 replies 82 participants last post by  kg6mov 
#1 · (Edited)
So here is the Ford Taurus Two-Speed E-fan Install. Here is the write up that I got some info from: http://www.jeephorizons.com/tech/fan/ I went to my local yard and found about 5-6 not even looking too hard. All the 3.8L Fords from 90-95 seem to have them, Sables, Lincolns, Taurus' you get the idea. Easy to pull, two bolts and clip the wires.

I cleaned up the fan and got a hold of some relays and wiring. I searched around and consistently many recommended a simple 30amp relay for LOW and a higher amp relay for HIGH. 10 gauge wiring for LOW, 8 gauge wiring for HIGH. I used just a standard 30amp relay for the low and a Ford Starter relay for high. The Ford Starter relay is plenty beefy to handle the initial draw that the high speed takes. It is also cheap too, about $11 from Napa. Here is the Napa P/N: ST404SB Oh and the hardware store I went to was ALL out of 8 gauge wire, ( don't ask me how they let that happen :dunno: ) so I bought 6 gauge. Sure it is overkill, but it is wired up and working so that is the way I am going to leave it.

I took an old battery that still had charge down to the basement to figure out wiring. No sense in messing around in the cold garage. Once I figured everything out it was pretty simple.

Here is a picture of the heavy duty starter relay wired up.


This relay is self-grounding. What that means is that when it is installed in its factory location, the metal bracket provided the ground. Since I was not mounting it in its factory location, let alone a Ford vehicle, I drilled a small hole in the metal bracket and threw a bolt on there with a circle crimp on connector, it is the green wire you see. The white wire connects to terminal "S" , this is the power lead from the switch I am using to control the fan. The bottom red cable goes to terminal "B" , which is wired to the positive terminal on the battery. The top red cable goes to terminal "M" which goes to the high wire on the fan.

Here is a picture of the relays wired up and their locations.



The smaller black box is the standard 4 pin 30amp relay for low. The white wires that go into the black wire loom and run along the firewall are to the switch mounted in the cab. Yellow wires are for the low speed, to and from the fan.
 
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#107 ·
This may be a dumb question that has already been covered but..... I keep seeing people talking about buying relays, fuses, temp sensor, etc...for the install. Why can't you just pull the needed items from the donar Taurus? I'm definitely a electrophobe when it comes to electrical stuff but I would like to do this to my 2.5 on the cheap/easy. It seems to me that the stuff needed for it to run right should be on the Taurus (follow the wires)?. Someone set me straight.
 
#108 ·
Yea i need to be set straight to as i very interested in this
 
#109 ·
more than likely, the taurus uses an ECU controlled system and the wires that power the fan arnt as "simple" as taking 1 wire from the batt, another from the switch, and rigging a relay.

The relay SEEMs complex, but its VERY simple. I didnt read all 8 pages, but just get a thermo-controlled trigger for the fans and forget em! Thats what ill be doing :)

Cliff notes: tracing the wires/relays/etc that control the factory setup is FAR more complicated than a 4 wire relay...
 
#110 ·
After thinking about it, I realized it was probably going to the ECU and yes, just easier to go find a relay elsewhere. Went to the junkyard this weekend and found plenty of fans and plenty of relays. Oh yeah, I read on here somewhere about Cadillacs having the waterproof relays and that is right also. I got several out of a Caddy, all I know is it was a "northstar?". I love the junkyard..... I recommend them to anyone.
 
#111 ·
Over the last year my wj has been plagued with cooling problems due to the relay and fan motor so I am really leaning towards doing a taurus fan set up on it but after tons of searching I still cannot find anyone that has put a taurus fan in a 4.0 wj. Does anyone know if the taurus fan will fit in my wj?
 
#115 ·
I got my relays out of a Cadillac at the junkyard while I was getting my taurus fan. I got three of them in case one didn't work. They were about $2 a piece I think. They were the heavy duty water proof ones. I don't know how much Amperage they are meant for but I think one was for the e-fan on the cadillac and they all had the same part #. My fan is working great. Oh yeah, they only have 4 wires on the plug, but five terminals inside the relay so I did have to rob a wire out of another plug to make a relay with the five wires. I would recommend the junkard relays before spending a bunch of money on new one(s).
 
#125 ·
Yea I have it pinched in with a fuse to give the relay signal now. But when I get the switch Ill send the signal to the switch then when I flip it to high it will turn low off but when its on low and when the jeep is off it will all turn off. Does that make sense? Instead of getting the trigger from the battery its coming from "Transmission solenoid" fuse.
 
#132 ·
Anyone do the swap with the 5.9 fan and sensors? How would you wire it using the sensors so it comes on and off automatically?
 
#134 ·
so i got my dc controls 2 spd unit, and i decided against using a 17 year old fan from a taurus, so i started shopping around for different options, and i found an excellant one, if you're willing to spend the dough. its from Derale, part number 16919, its a 2 speed, flows 2400 cfm, and the metal shroud almsot fits the zj radiator perfectly.. just a thought for anyone not wanting a junkyard replacement.
 
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