It has happened to me! (Dreaded Fan Sensor - Crumbling Hose!)

[HeatXfer]

Better to be a hoser than a hosee

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[HotPepperRedRanger]

Better to be a hoser than a hosee

Thank you, very helpful.

 

[HeatXfer]

Thank you, very helpful.

I'm here all week. Try the veal.

 

[HotPepperRedRanger]

I'm here all week. Try the veal.

Looking forward to next week. I hear we have funny amatures on the schedule

 

[HeatXfer]

Looking forward to next week. I hear we have funny amatures on the schedule

Ouch.

 

[NotBudule2]

Ouch.

 

[TJC]

You all's lame attempts at poetry is driving me crazy!
But if I don't join in, you'll all think I'm lazy.

My bride just sent me this ...

"Thirteen Hundred and Sixty Six!​

No hiccups, bumps, whines, or ticks​

I am happy, I am proud​

My husband's work is very sound​

He can keep it for today​

My fears and doubts have gone away"​

I think I know, I do believe...
That I have been given a short reprieve!

 

[airline tech]

Well damn. I was driving on the highway at 65-70 MPH Saturday and all hell broke loose. Hard transmission jerk, loss of power, dash looked like a Christmas tree. I was about a quarter mile from the exit to my local dealer. Limped to the dealer. Initial diagnoses was wiring harness failure Into the fan. I looked at the tech like he was from Venus, and he said a failure allows the fan to damage the wires and causes all of these issues. I am waiting on parts. My Ranger is a 2019 with 89k miles. What a poor quality design.

Since, this issue is not 100% confirmed by a Ford Tech. ask for specifics on this.

1. Is the support hose (the root cause) (Breaking Down - Heat and Wear)

or

2. Does the Fan Clutch, Fail and Lock up and create extra tension on the Hose

or

3. A combination of both

As I am trying to determine, if you disconnect the hose or it is broken
Some are staying in place and only requires the hose to be repaired (Modified) and some are
being twisted down (pulling) the harness down with it - hitting the pulley bolts, and then the catastrophic (Ripping) the harness apart.

I have not figured out what is causing the twisting (rotation) of the module, is it actual Fan Clutch Failure or just (flip a coin) if the hose breaks and the module just happens to catch the back side of the hub.

 

[TJC]

Since, this issue is not 100% confirmed by a Ford Tech. ask for specifics on this.

1. Is the support hose (the root cause) (Breaking Down - Heat and Wear)

or

2. Does the Fan Clutch, Fail and Lock up and create extra tension on the Hose

or

3. A combination of both

As I am trying to determine, if you disconnect the hose or it is broken
Some are staying in place and only requires the hose to be repaired (Modified) and some are
being twisted down (pulling) the harness down with it - hitting the pulley bolts, and then the catastrophic (Ripping) the harness apart.

I have not figured out what is causing the twisting (rotation) of the module, is it actual Fan Clutch Failure or just (flip a coin) if the hose breaks and the module just happens to catch the back side of the hub.

I do not think the Fan clutch locking up would do it. Best guess... Sensor binding on the shaft would. Hose too pliable. flexible, to keep the sensor from axial play would assist in binding. Low quality hose that can't handle the occasional bind and begins to deteriorate magnifies the problem.

So I suspect a little bit of both. It doesn't take a catastrophic failure of either to see this happening. Once that sensor is not being held perpendicular to the shaft binding can occur.

Once the hose deteriorates from constant flex st the stress points, the sensor is allowed to float just a little too freely allowing axial movement. Then it is just a matter of time before the cable is pulled just enough to catch on something, and BANG! The deed is done.

Note the last incident. The cable was rubbed through to the copper, and never wrapped. It was laying on the spinning shaft just enough.

That's my theory, and it is why I went with a beefed up reinforced hose. I want to minimize axial play, keeping that sensor plate as 90 degrees to the shaft.

If mine blows up we will know that my assumption was incorrect. I should check under the hood!

One last thought. Since I changed out the hose I seem to hear the clutch engaging more at higher speed (the fan speed not the truck speed) than before. Could be that I am more sensitive and listening for it now. But it seems to activate more often. It still gradually spins up and down.

 

[5thranger]

I really think the reason the hose is not available by itself from Ford is that they believe the fan assembly is failing or has failed and pulls hose apart. Ford has used this system on other models for quite a few years meaning the hose and the issue is probably the design of the assembly used by Ford on the Ranger. I would bet that when you replace with new assembly the problem would never happen again as it is updated. Same reason they have not recalled other defective systems, they just replace the ones that break under warranty.

 

[Chris M]

Does the hose actually do something beside hold up that wiring?

 

[Stevedbvik1]

I really think the reason the hose is not available by itself from Ford is that they believe the fan assembly is failing or has failed and pulls hose apart. Ford has used this system on other models for quite a few years meaning the hose and the issue is probably the design of the assembly used by Ford on the Ranger. I would bet that when you replace with new assembly the problem would never happen again as it is updated. Same reason they have not recalled other defective systems, they just replace the ones that break under warranty.

Fan clutch with hose and engine end bracket is supplied by Mahle to Ford. Mahle supplies fan clutch’s to many OEM’s. Many OEMs have used some form of setup like this. It’s not exclusive to Ford. The engine side bracket and preformed hose are unique to the 2.3L and seem to be the problem child.

 

[5thranger]

Does the hose actually do something beside hold up that wiring?

I think it prevents normal operation movement while being a bridge for harness but when abnormal movement happens, and hose has aged it rips apart.

 

[Stevedbvik1]

Wondering if there was a change made to the hose at some time. I did the preemptive silicone hose fix on my 03/22 build. OEM hose was ok with a pretty distinct bulge/edge at the engine side. From other pictures that I’ve seen on here it appears the hose that I took off is a bit beefier. Measured.375 id and .600 od. Maybe someone can compare? Posting pics for reference

 

[underwhelmed]

Just checked my 2019 with 63k miles and it looks brand new.

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