I posted the following reply at another thread. You can find that thread at
TDR Roundtable > Turbo Diesel Topics, 2nd Generation (1994 - 2002) > 24 Valve Engine and Transmission (1998. 5 - 2002) > Running hot. Did I screw up?
My reply from that thread:
This is my theory, I repeat, THEORY, on how the fan clutch works:
The fan clutch thermostat senses the temperature of the air that is exiting the rear of the radiator. If it senses that the radiator air is too hot, it engages the fan to cool the radiator.
In order for this system to actually cool your engine, as opposed to cooling merely the radiator, you must transfer the engine heat into the radiator. A few things that I can think of can cause this not to happen.
1) A thermostat that is not opening properly to allow coolant to flow into the radiator.
2) A bad water pump.
3) Any other flow restriction.
If the hot water is not getting to the radiator, the radiator will remain cool and the fan clutch will not engage, even though the clutch is operating properly.
An easy item to troubleshoot is the thermostat. You can remove it and heat it in water to see if it opens. If it's not fully open by the appropriate temperature, it's bad. Or you can remove it and run the truck with no thermostat to see if the fan clutch then engages, or if the temperatures are closer to normal climbing a steep hill.
Troubleshooting the water pump is more difficult, but I'm sure there are forum members who can make suggestions on how to do that.
It sounds to me like at least a couple of overheating problems mentioned on this thread are not the result of a bad fan clutch, even though the fan clutch is not engaging when the engine is hot. Check for flow.
Loren