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Discussion Starter · #1 ·
I'm having troubles locating a fan solenoid and am being told I will have to by the whole assembly. It has the 3 pin solenoid and I've confirmed motor itself is good and solenoid is getting power, it just isn't opening and letting it run at speed. This has already caused me to blow the seals out of an AC compressor. It would be nice to pay a couple hundred as opposed to $750 to get it fixed. If anyone has any part numbers or leads, it would be greatly appreciated
 

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I have not been able to find a part number for the solenoid, but I think there must be on because I found a procedure for changing it. Keep in mind that the hydraulic fan is not a simple On/Off fan... it runs at incremental speeds. My scanner show 8 speeds.... whether there are more I don't know. Also, the fan is always supposed to run when the engine is at an idle albeit at a slow speed 100-500 rpm.

Here is the procedure from the 08 service manual

SOLENOID-RADIATOR FAN
REMOVAL
NOTE: If the solenoid removal and replacement
steps are performed quickly, then only a small
amount of steering fluid will drip from the radiator
fan solenoid opening. The small amount of leak-
age should not require prior fluid removal from the
power steering reservoir.
1.Disconnect the battery negative cable.
2. Raise and support the vehicle.
3. Disconnect the radiator fan solenoid connector (3).
4. Clean the area around the radiator fan solenoid (1)
of any debris.
5. While holding the solenoid body, use Torxா T40 to
remove the radiator fan solenoid.

INSTALLATION
CAUTION: If for any reason the hydraulic fan mod-
ule ground wire is removed from the hydraulic fan
module, reconnect the ground wire and tighten-
mounting nut to 10 N·m (89 in. lbs.). Failure to
ensure the ground wire is properly connected
could result in an electrostatic discahrge that
could damage the PCM.
1. Make sure that the two o-rings are in place. Notice
that the armature of the solenoid can rotate within
the body of the solenoid.
2. Install the radiator fan solenoid (1) into the hydrau-
lic fan module (4).
3. While holding the solenoid body, using a Torxா T40
tighten the radiator fan solenoid screw (2) to 16
N·m (143 in. lbs.).
4. Connect the radiator fan solenoid connector (3).
5. Lower the vehicle
6. Connect the negative battery cable.
7. Check the power steering fluid level, fill as necessary.

Sorry it didn't paste very good.
Ignore first picture below....I could not figure out how to delete it.
 

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Discussion Starter · #3 ·
Chirpz, I appreciate that. Unfortunately, I think that is for the gas vehicles. Mine is a 3 wire solenoid and does not have a Torx screw on it. Mine looks similar to this one listed for the 5.7L listed here http://www.factorychryslerparts.com/products/SOLENOID-Hydraulic-Fan-Control/4297568/05143201AA.html

I may just try ordering this solenoid and seeing if it works. I called a few dealerships and they all tell me that same thing that it only lists the whole assemble for the diesel. Almost seems like a joke that a bunk $20 part causes you to buy a $1000 assembly. I've tested everything and my hydro motor is fine and voltage is working as it should.
 

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That is the proper one.I just used that 05143201AA on my diesel.Now the fan ramps up like it is supposed to.Last fall the part was $89.00.When I bought mine this summer the price went up to $348.00 in Canada.I looked it up on Mopar USA and it was 168.00.
 

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Chirpz, I appreciate that. Unfortunately, I think that is for the gas vehicles. Mine is a 3 wire solenoid and does not have a Torx screw on it. Mine looks similar to this one listed for the 5.7L listed here http://www.factorychryslerparts.com/products/SOLENOID-Hydraulic-Fan-Control/4297568/05143201AA.html

I may just try ordering this solenoid and seeing if it works. I called a few dealerships and they all tell me that same thing that it only lists the whole assemble for the diesel. Almost seems like a joke that a bunk $20 part causes you to buy a $1000 assembly. I've tested everything and my hydro motor is fine and voltage is working as it should.
I got that info from the 08 repair manual and it was listed under the diesel engine. Of course that does not mean that it could not be wrong. I didn't actually go look at my 07 fan to check it out. The pictures listed for the diesel and the 5.7 gasser look exactly the same.

My fan has a little quirk... when it reaches 100% speed, it howls pretty loud. It has always done that. The howling was a mystery to me until one day I was experimenting with my scanner and noticed that I could test the fan on 8 different level...sure enough when it reached 100% it howled. I first noticed it around 12,000 miles...now I have 124,000 miles and it still howls.
 

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Discussion Starter · #6 ·
You guys are awesome. Literally saving me hundreds of $$ on this thing. I've had some pretty bad luck with this one so far and the dealer has more than obliged to rape me at any point possible. This eases the pain a little bit. Got the solenoid ordered.

fatfreddy, how did you remove this one? Is there in fact a T40 that holds it in that I'm not seeing? It looked to me like I would have to grind down a wrench to get in and unscrew it out.
 

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Mine didn't have the torx.To get it off pry the electrical part off then you can use an ordinary wrench to take it off.When I got the new solenoid it came in 2 pieces.You screw the one piece in then slide the electrical coil on.
 

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Discussion Starter · #9 ·
It all makes sense after looking at it again. I can move the coil on the stainless stud. Will try to get pics when mine gets in. Through all of this experience, this just makes me more frustrated with jeep. The fact that I called 3 different dealers total and they all told me the same thing, you have to replace the whole assembly. When in reality, Jeep needs to fix the way they list their parts so this is sold as a service part. Glad we have this forum to convey that information.

After I get this fixed, it's on to rebuilding the clutch pack in the transfer case since apparently it's perfectly normal for that POS to be toast in 100K...
 

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I had to go to the dealer today to buy some Power steering fluid ($26.00/quart.) While there I asked if they would sell me a solenoid for the fan...ha ha. I got the same story. Must buy the whole unit. Then he quoted me a price that was over $1000.00. I told him that that would dampen our relationship. Thankfully, I don't need one right now, but I had to ask.

I could have bought the fluid online for $16 but I would have to wait and with shipping, it came to $26 anyway.
 

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when i went to buy power steering fluid the guy tried to sell me the $9 normal stuff not the hydraulic stuff...good thing i caught it
 

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It all makes sense after looking at it again. I can move the coil on the stainless stud. Will try to get pics when mine gets in. Through all of this experience, this just makes me more frustrated with jeep. The fact that I called 3 different dealers total and they all told me the same thing, you have to replace the whole assembly. When in reality, Jeep needs to fix the way they list their parts so this is sold as a service part. Glad we have this forum to convey that information.

After I get this fixed, it's on to rebuilding the clutch pack in the transfer case since apparently it's perfectly normal for that POS to be toast in 100K...
any chance you could take a pic of the solenoid so i know what im looking at when i climb under there

maybe mines just caked in mud from offroading all the time
 

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Discussion Starter · #13 ·
Will do. I plan on getting pics when I actually do this. Right now waiting on the solenoid from an online vendor. Luckily my jeep is driven by the wife and kept spotless. In order to see it, you have to remove the small air dam then lay on your back and look up at the fan motor. It will be right there on the right side.
 

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yea i think i know the one, i was playing around with it last time i tried to see whats up

could i slide the connector part off the pin and clean it and slide it back on without actually unscrewing the solenoid from the fan???
 

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Discussion Starter · #15 ·
yea i think i know the one, i was playing around with it last time i tried to see whats up

could i slide the connector part off the pin and clean it and slide it back on without actually unscrewing the solenoid from the fan???
Ha, an odd question, but technically yes. The part consists of the coil (where the electrical plug goes into) and the body that is actually screwed into the fan. All this is doing is using electromagnetism to open the valve. Hoping mine comes in soon and I can get it done and get pics up
 

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Discussion Starter · #16 ·
Alright, solenoid came in so I got to work. First a little background on my issues that led up to this. Bought the Jeep in NC and brought it back to Florida. AC is a must down here and this one sucked. Bad. I was getting ready to deploy again and didn't have time to mess with it. Took it to a local shop that's pretty honest. Came back AC compressor is leaking. Fine...replace it with a stock chrysler product. $1300 and it's done and out of my way. As the weather gets warmer the wife says it'll be cold in the mornings, but come afternoon it sucks. She drives the truck through most of the deployment until I can sort it out. Had a 1 year warranty so I take it back to the place that put in the compressor. He now says high side pressure is 400psi, your fan clutch is out. I hadn't dove into at this point and I didn't realize it was hydraulic. He orders what he needs from the local dealership...obviously not what he needed. I was quoted $150 to do the job. I can replace a clutch, but he had taken the time to diagnose and didn't charge me anything so what the heck. He gets the part and calls to tell me it's the wrong part and the correct one is $850 plus 3 hours labor. looking at over $1100 out the door. :laugh: That ain't happening. So I dig in and found the TSB which led my down that path. Every dealership will tell you only the whole fan assembly is available. Complete crap. I'm not sure how we go about getting it changed, but Jeep needs to list this solenoid as a replacement on the CRD.

So, into replacement. The first pic shows the new solenoid and piston assembly. Honestly, I debated on just replacing the solenoid only as chances are that is what failed. But since I had everything, might as well just do it. The second pic shows the star washer inside the solenoid that holds the body of the solenoid onto the piston assembly. First pull off the air dam to expose ithe fan from the underside of the vehicle. Looking up you will see the solenoid with the wires going into it. Detach the wire harness. Pull on the solenoid body and it should pull right off. Find a 7/8" wrench/ratchet that fits in there that you can finagle around to get enough movement. The torque spec is 29.5 ft/lbs so it doesn't take too much effort to pull it off. Once it's broke loose I was able to use my finders to unscrew it the rest of the way. The O rings to give it some resistance, but it isn't bad. Now that it's broke loose, I put some oil in the new assembly just to get it lubed up. I also lubed the o rings with the same fluid. Have some towels handy as about 1/4 oz of fluid will drain out. Pull the old one out and slip the new one in. Torque the new assembly to the required torque...or use the TLAR method. (That Looks About Right). No need to overtighten. The o rings provide the sealing surface. Once done slip the new solenoid on the finger. It took some light hits with a wrench to get it on and snug. Make sure it is flat against the nut. There should be no space present. Now, to verify I left the harness off. Started the jeep and turned on the AC. I then stopped the fan. I then plugged in the solenoid and the fan came to life. the jeep was already warmed up and there was just the slightest noise from the fan. It wasn't howling, but there was enough to let you know it was working. I then unplugged the harness again and the fan slowed to its usual 100-500 rpm. Plugged it back in and it revved up again. Looks like it's working. So slap the air dam back on and call it good. The celebratory beer is always a welcome addition.

The last pic is the internals of the solenoid broken down. There is no appreciable wear on any part that I could discern, leading to more confidence that it is the coil itself that fails.
 

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I might be fighting a similar issue as my temperature will fluctuate a good bit with the A/C on in stop and go traffic (saw 219F max). With the bad solenoid, would the fan ramp up when you turned on the vehicle when already warmed? That is the only time I hear mine actually ramp up, then it slows back down.
 

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yea ive literally only ever heard mine on start up on hot days for a couple seconds then thats it lol
 
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