Dual Contour fans in YJ - JeepForum.com
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post #1 of 29 Old 08-26-2015, 07:49 AM Thread Starter
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Dual Contour fans in YJ

Wanted to make a dedicated thread for this to help with searching the topic. I will also post up this info in the infamous Ford Taurus Wiring Solution (cheap) thread as well.

Background: I have been having cooling issues ever since I redid my 350 exhaust from true dual to a y-pipe crossing under the oil pan. I have installed a champion 3 core radiator and have been running the Volvo 2 speed 16" efan (same as Taurus fan). For normal driving this set up worked fine. During low speed crawling I would get a temperature creep that had led to temps up to 250 degrees. Also highway speeds around 80 it would want to run about 225 degrees. I had no room to swap a thicker radiator so I started looking at the fan.

The factory Volvo shroud I was using has the fan offset. I needed this due to clearance issues with the water pump. I needed either an extremely low profile large fan or two smaller fans. After looking around I came across some CJ and mustang forums discussing the dual contour fans.

Looking over the dimensions of the shroud and depth these looked like they would do the job. The Volvo/Taurus fan is a 16" 2 speed fan. So the surface area the fan covers is 201.6in^2. The contour fans are a dual 12" fan giving them 226.2in^2 of coverage. About 12% more coverage. Off to the junk yard I went and $35 later I had my fans. The Contour or Mercury Mystique fans to look for are from 1995-2000 with the 2.5L V6. The 4 cyl came with single fans and apparently there are some out there with dual fans on separate shrouds (this is not what you want). Supposedly it is obvious when you see it, but I didn't run across any in the junk yard. The only modification needed is to cut the little mounting tabs off the sides. I ended up gaining almost an inch clearance over the Volvo fan set up between my accessories and my fans.



Volvo fan coverage:



Contour fans coverage:



Instead of making my Volvo relay work with this set up (which a CJ forum member has verified to work) I opted to go with the Flex-a-lite Variable Speed Controller FLX-31163. This was a pricey option, but the functionality couldn't be beat. It provides soft start, temperature adjustment, switchable hi/off, 30 second engine off cool down, also a + or - a/c signal which turns fan on a minimum of 60% and higher if needed. It is also compact and clean (Pictured above attached to shroud).

The contour fans are wired from the factory with a resistor for low speed located at the driver side bottom of the shroud. I would suggest grabbing all of the wiring you can if you want to wire this route. Note that from the factory they use a 60A fusible link. The FAL controller is only a 45A capacity, but the fans will never start at 100% so that current capacity is not needed.

Another wiring option that had rave forum reviews across the web is the Delta Current Control (DCC). This offers a full 0-100% control and high current capacity options. The only drawback is that It is a 1 man show and built to order. I have read that lead times have ranged from 2-6 weeks. Also If he decides he is done making them then that's it. No more product support. Here is a link to his site. http://www.dccontrol.com/selector.htm

Here are some other wiring diagrams you may find useful for a different wiring solution.

Factory Diagram:



Another set up:




I after dialing in my temp setting. I stay between 200-210 all the time. So I would report this as a success. I will try and keep this post constantly updated with new information I gather or that may get posted later in the thread so the information can be easy to find.

Updated 8-28-15

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post #2 of 29 Old 08-26-2015, 09:16 AM
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Nice job! Thanks for sharing another option for us e-fan guys.

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post #3 of 29 Old 08-26-2015, 10:13 AM
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very helpful post. i am running in to the same trouble on my 302 swap

I don't feel like working on anything at this time so i sold my yj.
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post #4 of 29 Old 08-26-2015, 10:57 AM
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Thanks for this! I need to find someone to weld some mounting tabs to my radiator so I can do this.


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post #5 of 29 Old 08-26-2015, 01:03 PM Thread Starter
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Quote:
Originally Posted by Randonexplosion View Post
Thanks for this! I need to find someone to weld some mounting tabs to my radiator so I can do this.
Funny I was actually reading through your build thread yesterday. I was going to suggest this. Then I saw your radiator doesn't have the tabs on the engine side like the factory ones.

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post #6 of 29 Old 08-26-2015, 03:26 PM
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Quote:
Originally Posted by 87TPIYJ View Post
Funny I was actually reading through your build thread yesterday. I was going to suggest this. Then I saw your radiator doesn't have the tabs on the engine side like the factory ones.
Good looking out


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post #7 of 29 Old 08-28-2015, 11:08 AM
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Hi, what´s the year and model of ford contour dual fans? Can be used in 4 and 6 cyl?
thanks
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post #8 of 29 Old 08-28-2015, 11:28 AM Thread Starter
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1995-2000. I will update first post with more info.

Edit: updated 1st post with Model/Year/trim level and another wiring option

Also can be used with any engine combo. Very low profile fans.

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post #9 of 29 Old 08-02-2016, 11:38 AM Thread Starter
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Hey everyones doing it!

Since all of the E-fan threads are popping up or getting resurrected from the dead. I thought why not bump my old one. Still running strong to this day!
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post #10 of 29 Old 08-03-2016, 08:00 AM
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It really is a fantastic write up. Glad to see it worked out (BTW, that fan controller is the ****, have it as well)

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post #11 of 29 Old 08-03-2016, 08:25 AM Thread Starter
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It really is a fantastic write up. Glad to see it worked out (BTW, that fan controller is the ****, have it as well)
Yes it is, very highly recommend it. Absolutely worth the $. The FAL controller worked seamlessly when I installed my A/C last month. Now when the a/c clutch is engaged the fans turn on.
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post #12 of 29 Old 05-21-2018, 10:50 AM Thread Starter
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Old tech bump since Photobucket released all its hostages.
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post #13 of 29 Old 02-21-2020, 09:15 AM
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I'm working on a custom installation of the Dual Contour/Cougar fans, figured I'd post some pix that would be helpful to those looking at a retrofit of some kind.

First, here's some shots of the Volvo 2-speed Fan from the mid to late '90's. Supposedly the same motor as the Taurus fan, and the guesstimates I've seen is that this fan is good for 3800-4000 CFM with zero static pressure (free-standing, no radiator). The fan is actually about 15.375" in diameter, roughly 200 square inches of coverage. The protective fan surround is about 16".:







Here's some pix of the Ford Contour/Mercury Cougar V-6 dual 2-speed fan system. I've seen guesstimates all over the place, but the consensus seems to be that its probably around 3800+ CFM with zero static pressure. These fans are about 11.500" in diameter, roughly 225 square inches of coverage. The actual protective fan surround is about 12".





The Ford Contour/Cougar unit is one of the slimmest dual fan setups I've ever come across... It measures about 3-1/4" thick from the shroud leading edge to the motor plate. The fan/hub do protrude in towards the radiator core, with the hub being about 1/4" off the radiator core itself. The fan blades are slightly back from that. I'm working on a dimensioned drawing and will add it when its done.



Here's a shot of the Contour unit mounted to a Jeep radiator.



Here's another picture showing the Contour Dual fans installed in a 461 cubic Inch mild BBC in an El Camino. I've corresponded with the owner and they're doing a very good job in California heat.



I have a OEM 2000 Cougar unit, and a brand-new Spectra unit. From what little research I've done and I have a friend that's a senior Ford tech... he says the OEM stuff most likely used Bosch motors, the aftermarket use a generic Chinese motor. Jim also said most of those Ford built units are good for 200,000 to 300,000 miles at a minimum, he has a very low opinion of the aftermarket stuff. And the shroud sections of the OEM units seem to be better quality molded pieces, the tools were obviously better made, the aftermarket one is a bit rougher. I'm going to try to use the OEM unit, my biggest issue right now is a quick wiring up to test the motors. They came from a Cougar with 120,000 on the speedo which is a little below average. AFAIK there's no NOS complete Contour/Cougar fans laying around to be purchased but you never know. Use Car-Parts.com to do a search for what's available locally, regionally, or nationwide. Good salvage yards will grade their parts and give you some specs on the donor vehicle to include mileage, condition, and price.

Hope this helps having some fresh pix and a little information. Ford doesn't publish specs on their fans, but they are all well known for their power and durability. I had the Lincoln MkVIII in my supercharged SVT Lightning for 12 years and never had an issue, cooling or electrical. That is the beast... probably 5500-6000 CFM.
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Last edited by Mike/Mass; 02-21-2020 at 01:00 PM. Reason: added facts
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post #14 of 29 Old 02-21-2020, 06:12 PM Thread Starter
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Thanks for posting up. I need to fix the pics in this thread to help others. Freaking photosuckit!
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post #15 of 29 Old 02-22-2020, 01:19 PM
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Quote:
Originally Posted by 87TPIYJ View Post
Thanks for posting up. I need to fix the pics in this thread to help others. Freaking photosuckit!
Switch over to IMGUR, that's what I did. I still have to download and archive hundreds of pix that are still on Photobucket.

I drew up a crude wiring layout for the OEM loom... I'm guessing on the power and relay connections, please suggest any corrections. Found it interesting that Fan #1 Green/Orange winds up having a triple heat-shrink joint, all three (3) wires are #10 gauge. The two (2) Black wires that were connected to the Resistor Plug also have a heat-shrinked joint with one #10 gauge and one #12 gauge.


Last edited by Mike/Mass; 02-22-2020 at 11:34 PM. Reason: added pix
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