Attention: TDR Forum Junkies 
Yo Hoot
TDR MEMBER
First I need to tell the story leading up to the debacle. It was pretty much my fault. Years ago I replaced the radiator and the trans cooler. I didn't notice in the repair manual that the lower part of the shroud was held in place by sliding down into four tabs on the main shroud. Remember this is an early 04 not the 4.5 with the engine mounted shroud.
I saw the two plastic push retainers and pulled them out thinking that was all that was holding the lower shroud in. I manhandled it and ended up breaking three of the tabs off on the main shroud. No worries I finished the job and replaced the lower shroud with just one tab and two push pins holding it in place. Was fine for a couple years.
Then I dropped a valve seat and had to have the motor pulled and rebuilt. After $15k and a couple of months all was good again... until we moved to Texas in May 2021. One day about 3 weeks ago we were driving around Tyler in the heat of the day and she started shifting funny. Coolant temp went up... A/C stopped blowing cold air at the red lights. I was thinking thermostat. Was fine on the highway... just got hot at the stops. Got home... looked up underneath and saw the fan clutch wire harness was ripped off by the fan. Purchased a new fan clutch and installed it.... from below cause you can.
Noticing the broken tabs on the main shroud again that secure the lower shroud, I made it a point to figure out a way to secure it without buying a new main shroud. Also the guy that installed the motor didn't install the push pins so that ended up being the reason the harness got sucked into the fan in the first place. The lower shroud was too loose and didn't keep the harness tight, away from the fan.
I installed the new clutch and installed two push pins . So the lower shroud was held on by one main shroud tab and two very tight fitting push pins.
I went for a test drive and everything seemed fine... until a few days later she started getting hot again. Crawled under and found the entire fan had unscrewed and was laying down the bottom. For some strange luck the only thing damaged was the 36mm nut. I simply did not tighten the nut enough. The end of the nut was rubbing on pulley bolts and got hacked up. I pulled the fan out and had to file the inside edges of the mounting nut to get the threads to start. Put a little blue loktite on it and this time made sure I used a piece of metal, in this case a flat file to lodge between the pulley bolts so I could keep the pulley from turning as I tightened the clutch.
All good..... until .... getting hot once again..... wire harness once again cut off. I was livid. Re-ordered the same clutch. When I got the new clutch I found a couple of interesting differences. The fin castings were a little different and the wire harness actually had a disconnect plug at the clutch so if the harness got damaged you can replace it. I also broke down and ordered a new main shroud so I can eliminate this once and for all, having all four tabs to secure the lower shroud.
The new design clutch fit perfectly. I installed the new main shroud and lower shroud. I was still a little concerned as the lower shroud still tended to bow in the middle towards the fan, bringing the cable closer to the fan. I decided to drill a couple of holes in the radiator bottom fan lip and through the shroud and install a couple of zip ties. Came out great....
Now here is the interesting part..
The first replacement clutch was identical to the original clutch. I still noticed not so great A/C during stops in the mid day Texas heat. Also noticed cooling not up to par but working. This new design clutch made it feel like the truck is brand new again from a cooling and A/C perspective. Don't know why but I'm happy for sure.
I saw the two plastic push retainers and pulled them out thinking that was all that was holding the lower shroud in. I manhandled it and ended up breaking three of the tabs off on the main shroud. No worries I finished the job and replaced the lower shroud with just one tab and two push pins holding it in place. Was fine for a couple years.
Then I dropped a valve seat and had to have the motor pulled and rebuilt. After $15k and a couple of months all was good again... until we moved to Texas in May 2021. One day about 3 weeks ago we were driving around Tyler in the heat of the day and she started shifting funny. Coolant temp went up... A/C stopped blowing cold air at the red lights. I was thinking thermostat. Was fine on the highway... just got hot at the stops. Got home... looked up underneath and saw the fan clutch wire harness was ripped off by the fan. Purchased a new fan clutch and installed it.... from below cause you can.
Noticing the broken tabs on the main shroud again that secure the lower shroud, I made it a point to figure out a way to secure it without buying a new main shroud. Also the guy that installed the motor didn't install the push pins so that ended up being the reason the harness got sucked into the fan in the first place. The lower shroud was too loose and didn't keep the harness tight, away from the fan.
I installed the new clutch and installed two push pins . So the lower shroud was held on by one main shroud tab and two very tight fitting push pins.
I went for a test drive and everything seemed fine... until a few days later she started getting hot again. Crawled under and found the entire fan had unscrewed and was laying down the bottom. For some strange luck the only thing damaged was the 36mm nut. I simply did not tighten the nut enough. The end of the nut was rubbing on pulley bolts and got hacked up. I pulled the fan out and had to file the inside edges of the mounting nut to get the threads to start. Put a little blue loktite on it and this time made sure I used a piece of metal, in this case a flat file to lodge between the pulley bolts so I could keep the pulley from turning as I tightened the clutch.
All good..... until .... getting hot once again..... wire harness once again cut off. I was livid. Re-ordered the same clutch. When I got the new clutch I found a couple of interesting differences. The fin castings were a little different and the wire harness actually had a disconnect plug at the clutch so if the harness got damaged you can replace it. I also broke down and ordered a new main shroud so I can eliminate this once and for all, having all four tabs to secure the lower shroud.
The new design clutch fit perfectly. I installed the new main shroud and lower shroud. I was still a little concerned as the lower shroud still tended to bow in the middle towards the fan, bringing the cable closer to the fan. I decided to drill a couple of holes in the radiator bottom fan lip and through the shroud and install a couple of zip ties. Came out great....
Now here is the interesting part..
The first replacement clutch was identical to the original clutch. I still noticed not so great A/C during stops in the mid day Texas heat. Also noticed cooling not up to par but working. This new design clutch made it feel like the truck is brand new again from a cooling and A/C perspective. Don't know why but I'm happy for sure.
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