FF Dynamics ZJ E-fan kit issues - JeepForum.com
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post #1 of 82 Old 04-05-2021, 01:21 PM Thread Starter
tetatdo
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FF Dynamics ZJ E-fan kit issues

So before I get into it. I know taurus fans and etc are easy to wire up. I didnt want to deal with wiring, trimming etc, and just doing a quick drop in of a specifically built kit.

So I emailed back and forth with FF dynamics for a week making sure their kit will work with the 4.0 ZJ and will fit, I specifically asked them if I need to trim the water pump bolts and they told me the fan will fit without modifying anything.

Well I get the kit last week and go to install it and the damn thing doesn't fit. The fan motor, as expected, interferes with the water pump pulley. So I emailed them and they let me know the depth of the fan is adjustable and to remove the 1" of spacers on the fan (okay... you'd think they'd set it to fit before shipping)... So I did that, it still doesnt fit.

Also noticed the shroud is significantly smaller than the radiator core, leaving around 20% uncovered. Dumb question but the shroud should cover a majority of the fan, correct?

I've emailed to let them know the issues Im having but I have a feeling im going to be out 300 bucks with this thing and no help from them. I'll keep you up to date on how it goes.

See pics below


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post #2 of 82 Old 04-05-2021, 01:31 PM Thread Starter
tetatdo
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57BA52B8-8B8D-467A-9666-7B96C61BA0B3_1617650531815.jpg   137CC807-BCD1-4895-A24B-11E2429D3F57_1617650549001.jpg   9594B9C2-EC0A-4EA5-90AA-6EF61FAD98B9_1617650983471.jpg  

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post #3 of 82 Old 04-05-2021, 01:53 PM
HighLonesome
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can you get rid of the bolts for the clutch fan?
or if the fan shroud can moved it looks like it will fit
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post #4 of 82 Old 04-05-2021, 01:54 PM
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What is the condition/ age of your motor mounts and transmission mount?

That shroud is a joke - the third picture really shows how undersized it is for this application.

-Tim
(2) '96 4.0s
#1-'10-'18
#2- HP30/Ford 8.8 - 4.56, OME HDs, 5100's, IRO Adj Arms/Track Bars
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post #5 of 82 Old 04-05-2021, 01:57 PM
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Quote:
Originally Posted by HighLonesome View Post
can you get rid of the bolts for the clutch fan?
They are studs with nuts that hold on the pulley.

He could probably replace them with bolts to eliminate the extending studs.

That would still be cutting it close.

Even with new motor/ transmission mounts the 4.0 moves quite a bit under load.

-Tim
(2) '96 4.0s
#1-'10-'18
#2- HP30/Ford 8.8 - 4.56, OME HDs, 5100's, IRO Adj Arms/Track Bars
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post #6 of 82 Old 04-05-2021, 01:58 PM
HighLonesome
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if the shroud can be moved, looks like it would clear
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post #7 of 82 Old 04-05-2021, 02:58 PM Thread Starter
tetatdo
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I didnt consider that the motor might flex and hit the fan if i trim the bolts down.

They were suggesting I trim the bolts down and should have enough clearance.

My motor mounts and trans mounts are in good shape. I replaced them a while back but only have put on about 10-15k since I have put them on.

I can mount it lower and it would not interfere with the pulley at all, but then I have to rig up my own brackets, which would put it outside of their installation instructions and thus issues with warranty.

I asked them why the shroud is so small, and they said its because the 16" opening, on a full size shroud would not allow enough air to pass through the radiator at speed.

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post #8 of 82 Old 04-05-2021, 03:09 PM Thread Starter
tetatdo
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man i love JF. you guys are way more helpful than the ZJ fb group, haha.

Good suggestions here.

Tetatdo
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post #9 of 82 Old 04-05-2021, 03:35 PM
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After 15 years of owning Jeeps and installing aftermarket parts to them, I've come to a conclusion that most aftermarket upgrade parts that mention "Bolt on installation" means you better prepare either for cutting, grinding, trimming or welding - or all of them

I would probably just trim the water pump pulley bolts as short as possible, looks like that would get you very close to fitting the fan & shroud.
I remember I had a problem in my 4.0 XJ (geez, it's actually over 10 years since I've owned one ) with a new water pump where the pulley studs were causing fitment issue and needed a little trimming.
The first replacement water pump I bought (Gates) for the ZJ 5.9 years ago interfered with the OEM 5.9 e-fan motor/ shroud, I had to trim the threaded part of the water pump hub/ shaft a lot shorter. It's annoying when you're buying parts that should fit as-is, and the first thing you do is take out the 4.5" angle grinder.
Thank god the last water pump I bought came with a shorter hub, but even that one is a *very* close fit to e-fan.


Are those FF Dynamics fan shrouds 3d- printed? How do you like the overall build quality? Any information on advertised CFM?

Good luck!

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #10 of 82 Old 04-05-2021, 03:35 PM
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I went to their website and they do call it a 'semi-shroud'. Can the entire fan/shroud assy be moved side to side? It's impossible to tell how the assy attaches to the radiator.
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post #11 of 82 Old 04-05-2021, 03:43 PM
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^- I agree.

One thing I'm wondering is the radiator thickness - my Radiator express radiator certainly had the side tanks closer to firewall than the OEM radiator, which in turn caused the steering gear to actually rub against the radiator. It's been fine, but I ended up placing a thin sheet of rubber between them. Radiator core is also slightly different thickness but it's not causing a problem on the 5.9

With the 4.0 where the engine & serp. belt driven parts sit pretty far forward anyways, 3/8"...1/2" difference in radiator thickness or it's location can make a huge difference.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #12 of 82 Old 04-05-2021, 04:32 PM Thread Starter
tetatdo
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Quote:
Originally Posted by Timo_90xj View Post
After 15 years of owning Jeeps and installing aftermarket parts to them, I've come to a conclusion that most aftermarket upgrade parts that mention "Bolt on installation" means you better prepare either for cutting, grinding, trimming or welding - or all of them

I would probably just trim the water pump pulley bolts as short as possible, looks like that would get you very close to fitting the fan & shroud.
I remember I had a problem in my 4.0 XJ (geez, it's actually over 10 years since I've owned one ) with a new water pump where the pulley studs were causing fitment issue and needed a little trimming.
The first replacement water pump I bought (Gates) for the ZJ 5.9 years ago interfered with the OEM 5.9 e-fan motor/ shroud, I had to trim the threaded part of the water pump hub/ shaft a lot shorter. It's annoying when you're buying parts that should fit as-is, and the first thing you do is take out the 4.5" angle grinder.
Thank god the last water pump I bought came with a shorter hub, but even that one is a *very* close fit to e-fan.


Are those FF Dynamics fan shrouds 3d- printed? How do you like the overall build quality? Any information on advertised CFM?

Good luck!

I gotta say the built quality is good, the shroud itself is aluminum and is welded in the corners and sanded down. its built pretty beefy and the controller kit looks really well made. I cant fault them on any of that. I did last change the water pump in 2016. I want to say it was a gates one as well, but not sure because its been so long. I'm okay with trimming the bolts or putting in shorter ones but what pisses me off is i SPECIFICALLY asked them before purchase if that was necessary and they said no.

one of their ebay sellers claims 3600 CFMs and only about 16 amps of current draw, but I have not yet tested. Im about to hook it up to my DMM to check the draw. I dont have an easy way to check CFM, so I'll have to take them at their word and hope my rig doesnt overheat on a hot day in the desert.

To their credit though, theyve been quick to respond with inquiries and support emails.

As far as fitment, I have maybe about an inch of movement side to side, which makes absolutely no difference in regards to clearing the water pump pulley, but I have about 4-5 inches of clearance top to bottom, and if i place it low, it will totally clear the pulley, however the tabs on the top of the shroud rest right on the radiator fins. Plus I'm not too keen on having to rig up some sort of bracket that spans that length and doesnt flex. I fear anything going down to the brackets that far down will rub on the radiator and damage it. They suggested I can place it low and clear the pulley as well, but again. Why do I have to right up something I paid to fit?

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post #13 of 82 Old 04-05-2021, 04:34 PM Thread Starter
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Quote:
Originally Posted by Timo_90xj View Post
^- I agree.

One thing I'm wondering is the radiator thickness - my Radiator express radiator certainly had the side tanks closer to firewall than the OEM radiator, which in turn caused the steering gear to actually rub against the radiator. It's been fine, but I ended up placing a thin sheet of rubber between them. Radiator core is also slightly different thickness but it's not causing a problem on the 5.9

With the 4.0 where the engine & serp. belt driven parts sit pretty far forward anyways, 3/8"...1/2" difference in radiator thickness or it's location can make a huge difference.
it COULD be the radiator? It looks stock to me. i had it changed in 2006, and other than fitting fans, Ive not have any other issues with it. it looks like it fits perfectly

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post #14 of 82 Old 04-05-2021, 05:05 PM
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FF Dynamics ZJ E-fan kit issues

You want 4000 cfm or better. The 5.9 fan, Taurus fan, Lincoln Mark VIII fan all pull 4000 or more. That shroud is great if you only want air pulled through 70 percent of the radiator lol.
Over all this looks like a very irritating experience. If they won't accept a return I'd just make it work and think of it as a fun experiment.
Whatever the outcome this information is valuable for others.

Also the express radiator I installed fit like crap and didn't cool as well as the factory radiator in my experience.

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post #15 of 82 Old 04-05-2021, 05:21 PM
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From a quick search the threads on the 4.0 water pump flange should be 5/16-18 (don’t quote me on this I see some people saying they are m8-1.25. Maybe get 4 of each?) You could get bolts with low profile heads to avoid trimming the studs. I’d use blue locktight just for insurance.

-Tim
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