I'll give you one guess . . . . . Fan Clutch AGAIN!

[GShail]

As many who will read this thread already know, I have been through 6 and now make it 7 fan clutches on my truck within the last 50,000 miles.



Last time I posted anything I told you that in the absence of being able to find an explanation for the failures that I was going to replace all of the parts related to the fan clutch. I replaced the fan pulley, idler pulley, fan blade, fan clutch, even the crankshaft dampener. The truck had been to 3 different dealers, one specialty shop, plus I called all over America troubleshooting the problem over the phone. I posted my problem and asked for YOUR reccomendations. I tried every tip without success.



3 days ago I thought I had the problem licked. Fan clutch and water temps were as they should be. Before the replacement of the related parts the fan clutches were going out at a rate of about 4,500 miles, and I had made it well past that. After the replacement of the related parts I made it to 8,560 miles . . . . until yesterday when the fan clutch failed again while climbing a steep grade (Cajon Pass, CA) after being in some stop and go traffic.



Prior to this occurrence the truck has performed flawlessly with no strange sounds, a hand calculated towing mpg of 12. 2 and seems to be a happily running truck.



I was towing a moderate load (67 Mustang, 02 Jetta, 05 Freelander). My EGT's never exceeded much over 900 degrees for the sustained climb at an RPM of around 2,200 to 2,600, 5th gear.



I did have a code P0541 - Intake Air Heater Relay Low.



They warrantied the fan clutch and gave me a new one and the truck is fine again now.



It is going to go out again. Why is this happening?



I guess I will have to have a new fan clutch on hand with me at all times along with the special wrenches for getting it off.



Really, Really, REALLY would like to get this problem figured out.



Please help me my TDR brothers.

 

[jwduke]

Water pump shaft bent?

 

[Msilbernagel]

I posted my problem and asked for YOUR reccomendations. I tried every tip without success. [... ]It is going to go out again. Why is this happening?

If you've tried the mechanical, how about electrical? Any chance that it's rapidly turning the fan clutch on and off at certain times? Something like a bad relay, loose wire, intermittent short, temperature sensitive component, etc?



If you haven't already done so try and determine what electrical faults might cause rapid cycling of the fan clutch -- and subsequent early failure.



Have you examined the clutches? Is the failure mechanical, heat related, electrical? Might be some clues there.



Keep us posted, and good luck.



Mark

 

[rbattelle]

:--) I'm speechless (almost). I'd like to speculate on what else it could be, but I don't want to be responsible for leading you down a false path (again).



-Ryan

 

[tkerrigan]

You say that the clutch goes out, but you have'nt indicated just what part of the clutch goes out. Friction surface bad? Coils shorted or High resistance?

 

[Hercules130]

I would use the lemon law and get a new truck. 7 fan clutches is rediculous.

 

[GShail]

How do you go about using the lemon law?

 

[steved]

Water pump shaft bent?

I don't think the fans ride the water pump do they... I haven't checked my 04, but the 99s have a separate support bearing.



steved

 

[rbattelle]

I don't think the fans ride the water pump do they... I haven't checked my 04, but the 99s have a separate support bearing.



steved

This remains true on the common rail engines.



-Ryan

 

[Hercules130]

How do you go about using the lemon law?

i am not exactly sure how to use the lemon law, but it is my under standing that if a dealer attempts to make the same repair 3 times and is unsucessful , then they have to by the truck back. i am not sure how it would work if the first 3 repairs were made under warranty and then the third failed out of warranty. i am sure some one knows more about this than me though.

 

[MCecil]

How do you go about using the lemon law?

Here is the Idaho statute:

http://www.lemonlawamerica.com/state_laws/idaho.htm

You may be SOL if your truck is out of warranty, more than 24 months old or you have over 24K miles on it. Since it is not a safety issue (steering or brakes), the dealer has four shots to make it right within the limits noted above before the consumer can envoke the statute. That's how I read it, but I'm not an attorney.

Enjoy your day and God Bless,
Merv

 

[WDixon27]

i've never touched a 3rd gen truck but ill venture a guess or so, i gather it's a electric style clutch from this post, as a euro car mechanic i do a lot of ac work and a ac compressor clutch is pretty much the same thing and some mercedes use a electric fan clutch too, generally these things don't draw much power (2-5 amps usually) but they do get unhappy if they don't get enough power or a good ground they will slip and overheat cooking various components, discoloration of the metal and or flaking paint and rust colored dust are common. if the coil is crapping out it's hard to point at the cause, excessive vibration breaking up the windings, abrasive contact with something causing a short or a unsecured wire flopping around and snapping off. i hope i am being helpful if not oh well nothing ventured nothing gained

 

[R C Cola]

Fan Clutch Again ? ? ??

This is the reason I drive a first gen. I do not trust all electrical gizmos under hard use. Assuming that you are not dealing with faulty brand new parts, electrical problems have to be suspect. I would seriously consider doing

a conversion of the fan clutch to the old manual style like on the first gens. If the computor does not like that then you should be able to wire in a fake resistance to fool the computor into thinking it is there.

On the semi's we have installed a manuel switch on the dash to override automatic kick-in. No problems encountered. Some of our fellow members are pretty sharp on elect. stuff and will most likely helpout. Best of Luck RC Oo.

 

[steved]

I assume some 3rd gens came with a electric clutch and some didn't?? Mine doesn't have one.



steved

 

[nickleinonen]

I assume some 3rd gens came with a electric clutch and some didn't?? Mine doesn't have one.



steved

all the 3rd gens have electric clutches on the fans...



i've had one changed out and i never tow...



if it fails out of warrenty for me, it is getting a stand alone electric or 2... [low profile pusher in front of rad and puller behind maybe???]

 

[steved]

all the 3rd gens have electric clutches on the fans...



i've had one changed out and i never tow...



if it fails out of warrenty for me, it is getting a stand alone electric or 2... [low profile pusher in front of rad and puller behind maybe???]

Hate to tell you, but there is nothing electric about my fan clutch unless they hid the wires in the bearing or they control it by remote control :-laf ... I checked. I saw an earlier thread about it and checked mine when I first got the truck... no wires, looks like any thermal-type clutch.



Maybe a package thing? Mine's just a lowly ST.



steved

 

[Prairie Dog]

I assume some 3rd gens came with a electric clutch and some didn't?? Mine doesn't have one.



steved

Steve, they are hidden well!. If you lay on your back and look up at the fan, you'll see two wires running up a channel to the the clutch assy.

I was surpised to find this myself!



Scotty



EDIT: On second thought you may be rite Steve, I think it only electrically engages if the A/C is on so if you dont have AC then maybe it's not there.

 

[nickleinonen]

EDIT: On second thought you may be rite Steve, I think it only electrically engages if the A/C is on so if you dont have AC then maybe it's not there.

you can still get a truck with no a/c?????

 

[FASTERTHANU]

The engineer where I work (in Nevada) evoked the lemon law after the warranty had expired on a GM ride. Due to the fact that the 1st 3 repair attempts had been done under warranty that established a history on the vehicle. The dealer did not want to do it but we supply GM performance and were able to go to a regional warranty manager. good luck

 

[steved]

I have AC, but I still don't think there are any wires running to the fan... my fan never comes on by itself.



steved