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My Electric Fan Swap

61K views 114 replies 26 participants last post by  predatorbass 
#1 ·
The electric fan died on my Jeep a couple of weeks ago.. I plan to replace it with a Ford Contour fan that came out of a 1996 model. Once ordered, it came to my attention that these fans new or used rarely come with any wiring.

So here goes... Here is the old fan that came with my Jeep. Might be a Taurus. I do not know.


Here is my new (used) Contour fan minus the wiring.
Note the factory plug that came with it, Hackfab says these are pricey!
Look at all that room!
Here is a test fit, looks good. I do not even know if the radiator came out of a CJ or something else.

I will keep you guys posted on the progress.
 
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#71 ·
Yippeee! Got a box of 'em in and the ARE the right ones/size!
Thanks to everyone whom didn't find my cross posts annoying.


...and I have more faith in Czech manufacture than that of China. Also as I've promised on more than a couple forums if anyone else is building these relay sockets drop me a line and I'll mail you enough of these (2) to get your fan project going on this 70/80 amp relay!​
 
#73 ·
I'm still planning on using the resistor setup to keep things affordable and to kep my skills in tune.

Hmmm, mine were insulated with plastic shielding, if I'm thinking where you're referring to. Can you post a pic?
 
#75 ·
Thanks for the replies. I just made new wires and ditched the ones that came with it. Worked out great it's the first time since I had the Jeep that I can just sit and idle without the temprature climbing. I wished I had of done this a long time ago. I went with the FAL controller and it works great.
 
#86 ·
This IS one of the best threads on the site!
 
#88 ·
HI BB This thread has been very quiet for some time but I think Coiz is meaning that these go to ground, if I'm not mistaken. :) It is Coiz's diagrams that my setup is going to go by, once I FINALLY get this damm oil leak fixed.
 
#89 ·
OK, so I want to add some ideas to this because I've seen some great threads on others sites about the temp sensor set up. I give FULL credit to 99.8% of this to this thread: http://www.nastyz28.com/forum/showthread.php?t=200028

HOWEVER for jeepers we need to have a temp sensor that works.... so here is MY setup;

1 x jeep CJ8 with a 4.0 head and MPFI (not necessary but you gotta have A VEHICLE)

1 x Contour 2 speed, 2 fan - I have elected to use the resistor in the bottom left of the fan so that two fans come on with first trigger, stay on but increase speed for 2nd trigger.

1 BMW 2 temperature sensor - 61311378073 from a BMW 90's, always screwed into radiator however they are availabe from Rock AUto here: https://www.rockauto.com/dbphp/prt,107,61311378073

1 VOLVO 2 speed relay - as seen in the link - it's from 90's Volvo;s they were 9.95 each at picknpull in March 2013~ I snagged two and ONE WIRING LOOM / connectors to help it all go along

So far everything here is n line with the posts in the last 6 pages .

My biggest question was how to thread a metric 14mm temperature sensor (this one closes two circuits based on tempereature... 195 and 210 are triggers I believe) The thread above is the originator of this cool idea.....not me

NAPA did not have any threaded t-pieces that I could put inline with my 5/8 heater hose. HOWEVER by CHANCE I tried a NAPA 5/8 heater item that had a threaded connection and... it worked! Partt number 660-1414. It has 5/8 nipples and a thread that will work. AWESOME

So the BMW switch into the NAPA heater hose adapter creates TWO grounding opportunities for different temperature settings.

For me, both these grounding signals from the '0' pin can run to a (SPDT?) switch as in the original diagram, with a HIGH setting that automatically grounds the high if you will be winching while pumping tires with your compressor and stationary and just started the engine!, an OFF that turns it off for water crossings or simple desire, and a 'standard' setting that is automatic. Make sense?
 

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#90 ·
Looks like a good setup except for it looks like that controller was intended to run a single cooling fan on two speeds and not double fans, just wondering if it was designed to handle the load. You really just need two 60A relays and the two different temperature switches to achieve the dual speed operation you are looking for. Adding in the on/off/auto is easy. I can draw you a custom diagram if you tell me exactly what you are looking at doing.
 
#91 ·
Coiz, thank you - I really appreciate your offer! Here's what I have read - and tell me if I'm off base.... the Contour fan has a resistor that is somewhat inline with a single taurus fan start amperage for the slow speed and then the jump is somewhat the same as the jump to high speed. If that isn't the case, how much more does the contour slow speed/dual fan pull than slow speed/ 16" taurus? If the volvo relay set up is designed for a taurus fan lookalike (and again it's only what the wonderful internet has sent to my eyes), should it not be suitable for that drwa and if so, why not the the contour?

In answer to what i want is to have dual slow triggered by the thermo switch i have from the bmw, dual high triggered by either my AC signal (compressor) OR a manual overide PLUS an off for water fording!!! Should I try the volvo set up? Or do you think it wouldnt up to par?

I appreciate your help, continued commitment to the jeep 'hood' and to this thread....
 
#92 ·
Sorry for the late response, I've been a little busy lately.

You are correct in that the resistor simply lowers the available voltage to the fan(s) so that it will turn at a decreased speed. It does help with that initial start up draw somewhat.

The thing you have to remember is that the Contour dual fans are factory protected with a 60A fuse, basically 30A for each fan. The Taurus single fan is a 30A or 40A depending on what year you look at. That Volvo controller looks to be rated to 30A from what I can tell by the main red input wire. Is a single 30A relay enough to power both fans factory protected at 60A? Probably and you might not ever have a problem but it would certainly be under protected.

Another thing in regards to the Volvo controller is that, if the diagram you posted is correct, it is a true two dual speed relay setup in that the fan must be running on low speed before it can turn on the high speed. That is one of the downfalls to that type of controller, if anything happens to the low side control you lose all fan operation. This makes it so you can't just default on the high speed fan whenever you want unless the low speed is already running or you wire in a second switch. The way he has it drawn in the diagram should work fine for Off and Low but I doubt it works on High. We can find out for sure if you take one of your controllers, power the Red (A1) and ground the Yellow (B2), and tell me if it clicks. Keep in mind the Red (C2) will be hot if it does click.

i want to have dual slow triggered by the thermo switch i have from the bmw, dual high triggered by either my AC signal (compressor) OR a manual overide PLUS an off for water fording!!!
I can make a diagram showing you exactly how to wire both controllers to make it like that my only concern is the size of a single 30A relay powering both fans and the fact you will also have to wire in an extra cutoff switch for the low speed fans.

Another option would be to have one controller run the left fan on medium speed triggered by the thermo switch and use the second controller to run the other fan on High based off your A/C, thermo #2 or manual switch. Again, you'll still need two switches to be able to cut off the low speed fan. I also don't know if one fan would be able to handle the majority of your cooling.

At this point I think your best bet would be to either get two 60 amp relays or just double up your Volvo controllers so that they both share the load to the two fans. Wire it exactly like he has in the diagram you posted just splice the feeds and signal wires together. The switch he has should work fine for Off and Low but I am not sure about being able to turn on High. I am really curious to know if the relay clicks when you power the red and ground the yellow wire.

 
#93 ·
Wow! Even with an etchasketch I can't do that! Well I'm happy to run the volvo relays or not...



I would say that you are way better at this than I - clearly - and I would default to your better judgement. I have a 75A relay and multiple 40A's. IF I ignored the Volvo relay and went for a 75A and a 40A (or two) AND wanted to use that BMW switch I am so very proud of..... what would that be? That sounds like it would be better..

The only triggers would be thermo switch 1 or 2, A/C or manual! That sounds easier than trying to put a Volvo peg in a Jeep hole! Agree?

PS. THANKYOU for taking the time....
 
#94 ·
If I had three relays and was trying to accomplish what you are trying to do, I would wire it one of two ways.

The following would give you a master On/Off for water crossings, both High and Low would be controlled by the Thermo switches and you would have a way to default the High speed fans On or give the A/C control of them. I have A/C Compressor Coil + listed in the diagram but it would just need any 12v input when the A/C is on. If your A/C is somehow a ground input, the relay and switch can easily be wired that way too.



The following still controls both High and Low speed fans with the Thermo switches. It removes a manual switch but also takes away your ability to turn the fans manually on High, you would only be able to default them to Low speed. Also with this setup, if the A/C is commanded on, the High speed fan would still be able to run with the manual switch in the Off position. So you would want to make sure the fan switch and the A/C switch are both shut off for water crossings. The only benefit to this is one less switch to wire because you already have the A/C switch to keep it On or Off.

 
#96 ·
If I had three relays and was trying to accomplish what you are trying to do, I would wire it one of two ways.

The following would give you a master On/Off for water crossings, both High and Low would be controlled by the Thermo switches and you would have a way to default the High speed fans On or give the A/C control of them. I have A/C Compressor Coil + listed in the diagram but it would just need any 12v input when the A/C is on. If your A/C is somehow a ground input, the relay and switch can easily be wired that way too.....


COIZ, thank you! I tried TWO things - leaving the VOLVO relay to do its job with a 30A fuse - fine for low volume, bad for high volume (airflow) - So, tried it with a 60A, no problem... Volvo works like a champ..

HOWEVER I ALSO set up YOUR system and it works flawlessly. So thank you again

The Volvo PLUS a 60A single fuse plus the BMW thermoswitch (195/205) works fine....for those that don't want to wire multiple relays.... the VOlvo 'thing' is all singing all dancing works like a charm.

For those that trust part stores to have relays, COIZ solution is more reliable, more 'buildable'. For those that want to cobble parts from a junkyard, volvo 'seems' to work high and low, with a contour using their resistor! Nuff said!!!
 
#101 ·
If I had three relays and was trying to accomplish what you are trying to do, I would wire it one of two ways.

The following would give you a master On/Off for water crossings, both High and Low would be controlled by the Thermo switches and you would have a way to default the High speed fans On or give the A/C control of them. I have A/C Compressor Coil + listed in the diagram but it would just need any 12v input when the A/C is on. If your A/C is somehow a ground input, the relay and switch can easily be wired that way too.....

COIZ, thank you! I tried TWO things - leaving the VOLVO relay to do its job with a 30A fuse - fine for low volume, bad for high volume (airflow) - So, tried it with a 60A, no problem... Volvo works like a champ..

HOWEVER I ALSO set up YOUR system and it works flawlessly. So thank you again

The Volvo PLUS a 60A single fuse plus the BMW thermoswitch (195/205) works fine....for those that don't want to wire multiple relays.... the VOlvo 'thing' is all singing all dancing works like a charm.

For those that trust part stores to have relays, COIZ solution is more reliable, more 'buildable'. For those that want to cobble parts from a junkyard, volvo 'seems' to work high and low, with a contour using their resistor! Nuff said!!!
I know this is an old thread, but do you know if the single Volvo relay held up? Im switching over from a single 2 speed fan to the dual contour fans. I already have the Volvo relay wired up and if I can use it for the contour fans that would be awesome.

Thanks!
 
#97 ·
My hat's off to Coiz and our comerad's of the same idiom. Taking the time over and over to help neophytes like myself and others of greater skill is sorely lacking these days it seems.
 
#99 ·
I've finally pulled the stock shroud and the Hayden E fan that was part of the setup on 'Black Betty' when I first got her. Turns out that the Hayden fan circumference was only slightly larger than the twin Merc fans. Got the radiator out and compared the Merc Mystique fans/shroud and it looks like it will fit tight and completely cover the raditaor core. First bit of trimming was the top clip of the shroud to get tighter fit of the shroud.The idea being that air will follow the least path of resistance so I want a right tight fit compared to the previous setup...



Tonight hope to have energy enough after work to finalize trimming and taking more photos for the archive.

Update: http://www.jeepforum.com/forum/f8/contour-fan-factory-speed-control-552543/index7.html
Sorry for not posting photos here but I've been called on being repetative so I'm hoping link posting will be okay.
 
#100 ·
After trimmng that top bracket the shroud slipped right in and although had to get a little creative with how I bolted the lower left corner this mod is as easy as many have said it is.



Now it's onto the wiring and a general cleanup of the wiring in the engine compartment using that Ford PDB I got a while back. Having sticker shock at how much those Maxi fuses go for, I went out to the boneyard and got a full complement of blade fuses and one 60 amp for the 70 amp relay that's going towards the fan setup. I also finally found the correct color of visors for 'Easy Bake' and ALL FOR FREE :2thumbsup: No, I didn't steal 'em.

 
#102 ·
87TPIYJ said:
I know this is an old thread, but do you know if the single Volvo relay held up? Im switching over from a single 2 speed fan to the dual contour fans. I already have the Volvo relay wired up and if I can use it for the contour fans that would be awesome. Thanks!
im still using same setup. Volvo relay. 60 amp fuse, bmw thermo switch. I amended mine slightly so that low fan comes on at 205/210 whatever the switch is, and high on an on/off switch separately. I wanted to be able to run no fan for water and use high if running conpressor regardless of engine temp. The high switch also grounds the a/c line to raise rpm a little. So... Go for it!!
 
#103 ·
Awesome that's what I wanted to hear. I have a 70A solenoid I use for killing power right now. I just got to test the fans I pulled today and my resistor is shot. I'm going to go back to the yard and see if i can grab another resistor tomorrow. I picked up a online fuse holder and some 60A fuses. Hope to get it back together before the weekend. Also hope it helps with engine temps over the 2 speed volvo fan. Which was so far off center on the shroud it really only pulled air through half the core.



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