After my recent 5+ hour drive with a stuck fan clutch, I'm considering this mod. I know there are a couple of good e-fan writeups with pics and parts lists. Does anyone have links?

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OhioLariat,
If I were you, I would rather ask white89 and AK here to give you their recommendation than looking for old threads. Both have hands-on experience.

 

I will have to do a thread when I do mine. I just FINALLY found a quality 44 mm temp sensor housing for the upper hose. So, now that the truck can just sit and be fine for the summer (it is no longer my DD), I can actually do things slowly - and do it perfect. LOL.

I just need to drill and tap the 44 mm to accept the BMW sensor (M14 X 1.5).

 

I look forward to seeing that. Are you going to go with the new-style fans? That seems like the most straightforward and effective.

EDIT: Found DCC Controllers mentioned in another thread, and thought I'd add the link for future reference. Any input on these?

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I am probably going to stick to plan A with the Cougar fan I already have. But that link I posted earlier in the thread of the 2010+ fans is awfully tempting.

I need to find the dimensions of that 2010 fan though.... because my goal is to get 100% coverage of the radiator. So mounting the fan in the shroud (like I did on my Mustang) is most likely what I will do.

 

white89,
The photos that you linked show how well 2010 shroud fit 2007 radiator. 2007 and 1997 radiators are within 1/2". I am sure 2010 shourd will fit 1997 radiator.

Here is a very long thread with much info on 2010 e-fan for next gen F150. https://www.f150online.com/forums/ot...ns-spal-7.html if anybody is interested. Very tempting. My main hesitation is that I have to go through the fan fitting process again and high current demand.

 

That is another reason I prefer the 2 speed single fans. Current draw. When you go from low to high the current draw is minimal. I need to get a DC amp clamp sometime and see some exact figures. The initial startup is where you get a big draw.

 

I am not talking about initial surge current. Internet search points to 15A each for the dual fan, total 30A. But I found a couple of posters contending they measured 60+ A steady current with current probe and multimeter. According to the linked 2010 Ford fan thread, folks ran it with a 30 to 50A controller and 10-12 gauge wires. I doubt 60A but am scared to buy one without assurance. I asked ebay seller. They didn't have the info.

I have a 3-relay setup. It puts dual fan in series at start, and switches over to parallel for full current draw. No surge current issue.

 

The Volvo's use VDO two speed fans as well. Their fans are pretty decent too, but the sizing isn't all that good for a V8 car. But this is why the Volvo relays are a great solution. I have yet to see one die. I've never pulled one that was defective either. They are rated for 30 amps, but I guarantee they see an initial current draw over 30 amps. Can't find my link, but I recall someone doing tests saying the Volvo relays were handling a 60 amp spike.

I am running a 60 amp continuous duty relay, and running the whole system through a 40 amp breaker.

 

Good to know. I will share this info with others. Thank you.