Fan clutch replacement...'03 5.9

[GI Joe]

Not a lot came up on my search, so I'll ask it here..

I've got a fan clutch replacement project this weekend, and am looking to make it as easy as possible...

So far, I've gathered I need a 36mm open end wrench(for fan hub nut),
possibly a large C-clamp(to hold pulley from rotating... I rented the tool set from FLAPs and it didn't fit anything for this job,
and 10 and 13mm box end wrenches(for fan blade to clutch bolts and to remove a couple pulley bolt for room for the wrench...)

From your experience, Anything else I should need?

Also, does anyone know where the wiring goes on the frame(that the fan clutch plugs into)? My wires were cut and plugs removed at some point by a PO(maybe for manual control with a tuner?? *shrug*)..
I'd like to replace that chunk of harness, if it's plugged in somewhere at the other end..

Thank you!

 

[Joseph Donnelly]

I don't have my back issues handy, but I covered replacement of the fan clutch several years ago.

 

[cerberusiam]

The dealer should be able to get you a pig tail for the truck side of the harness if that has been removed. The set from any of the parts stores with the holder that grabs the bolt heads works fine to bust it loose. Just remember, right hand threads on the clutch assembly.

 

[GI Joe]

I'll check on the pigtail..... I hope to find one at a wreckers yard...

I will try the tool from another FLAPS, as the one from Advance didn't work..

 

[Tuesdak]

The plug is physically located on the passenger side bottom of the fan shroud. It's not uncommon for the wires to get sucked through the cooling fan esp. if the hold down on the bottom gets loose.
Note there are a couple of plastic fasteners on the bottom of the shroud to allow part of the bottom to come apart. I suspect this allows the rest of the shroud to be pulled straight up w/o fan removal. This way you don't have to remove both the fan and shroud at the same time. The coolant overflow is also in the way as well as the upper radiator hose.

The PO on my truck missed one of the radiator to fan shroud lower catches the shroud slides into on the radiator and used a zip tie rather than re-doing the job properly. So double check these before putting everything else back on.

I suggest cardboard between the fan and radiator to protect the radiator when, not if, you drop the fan into it.