Anybody else experience a fan clutch going bad?

[LVTremor]

I’ve had my truck at the dealer multiple times for the clicking noise that is coming from the fan clutch. The truck is actually at the dealer now for multiple issues that need to be fixed before 36,000 which is in 500 miles. Like usual they are telling me the clicking noise from the fan clutch is normal. ?

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[TJC]

Hey Fitz, in the link below is video of your exact sound - Confirmed Fan Clutch

Engine noise "ticking/clicking" | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

I only heard the chirping from inside the cabin, but the length and frequency of the sound are eerily similar.... and softer, as expected with doors closed.

 

[TJC]

I wonder just how much the Fan sensor readings impact the system. For instance, if the sensor stays connected but no longer measures rotational fan speeds, what would be the impact? Throw a warning DTC, but drive fine, or put the truck in limp mode.

Anyone care to hazard a guess?

I'm thinking throw on an old school reliable clutch fan and simply leave the sensor connected and out of the way.

 

[Muffin1]

Mention to them that the clicking wasn't there when you drove it off their lot brand new, if it was 'normal' like they say why hasn't the click been there all along.

 

[GitRDone]

I'm a bit confused (but that's pretty normal). Since the fan clutch is locked up for a few minutes until the engine warms up a bit and the oil in the fan clutch distributes, why would damage occur if it locks up inadvertently after the engine is warm?

 

[airline tech]

I'm a bit confused (but that's pretty normal). Since the fan clutch is locked up for a few minutes until the engine warms up a bit and the oil in the fan clutch distributes, why would damage occur if it locks up inadvertently after the engine is warm?

The Fan clutch will engage and disengage depending on various engine parameters (Inputs)

The Fan Speed is controlled by engaging the clutch and controlling the time the actuator is opened. (This Timed event) controls how much fluid is moved from the reservoir to the working area. (The feedback for the amount of fluid that was moved) is the Fan Speed Sensor.

Here is a short video on Elect Fan Clutch Operation I found.

Not the same fan clutch in the Ranger but gives a basic understanding of operation.

BorgWarner Visctronic - YouTube

The damage that owners are having is not being caused by the Engagement / Disengagement of the clutch itself. (Normal Operation)
It is being caused by something wearing out (Bearing / Raceway) in the clutch Assy as when that transition happens is applying abnormal torque on the electric module.
and or
The support hose is breaking down and breaking and thus taking away the support.

My Ranger does not show any strong movement on the module. I can VERY CAREFULLY reach down and grab the module at both (Engaged / Disengaged) and rock it side to side without any resistance from the rotating fan.
So, what this tells me is that there should not be any large amounts of torque being applied to that module. (Engaged or Disengaged)

So, since some have reported they only have a broken hose, then this may be just a hose issue.
But what I cannot determine with great certainty is to why even with the hose breaking there should not be any great force being applied.

Now we visit, the Total Failure, and the module spins with the fan. and destroys the harness.
My theory it is a Bearing or Raceway, binding up and the clutch is rocking back and forth, this movement is Pinching the module between the clutch hub and the nut, forcing it to spin along with the fan.
or
Internal failure or the clutch and the actuator valve, possibly causing an imbalance or a kickback in the clutch assy. I'm thinking it terms of hydro lock or backfire if you will.
Possibly a higher-than-normal pressure buildup in the Working Chamber, the actuator valve sticking and not allowing it to disengage to release the fluid back into the reservoir.
This action causing a momentary bump / jolt in the clutch that is rocks backwards on the shaft, thus also pinching the module.

Again - These are just THEORIES.

 

[TJC]

The clutch is not locking up. The clutch sensor & power module is designed to float freely on the clutch shaft. It is held in place by a flexible rubber hose that bridges over the fan belt from the front of the engine to the clutch fan. The hose also has the power and sensor cable piggybacked on it.

There have been cases of this doughnut style module freezing up on the shaft. When this happens the rubber hose breaks allowing the module to spin with the fan. The module control cable wraps around the fan shaft until it breaks, destroying the cable, which shorts out the circuit... that then blows a fuse that powers at least 6 other functions including the oil pressure pump regulation. Your truck dash lights up like a Christmas tree, and immediately reports low oil pressure and a host of other unrelated issues, and goes into limp mode.

Very poor design by Ford.

Edited - Airline Tech stated it better than me....

 

[airline tech]

Well, I had a day.
While working on my daughters' boyfriends 2019 Ranger XLT, guess what I found.
A nice little broken hose, I played with it some as I wanted to compare his vs mine.
I noted allot of slop in the module as compared to mine.
Well, I ended up grabbing some extra 3/8 HP Fuel Line I had in my spare line box and added (2) clamps.
OEM Hose was deteriorated pretty badly and crumbled in my hand.

So, we can add another failure of the hose to the list.
I will have him monitor it.

 

[RedDakooter05]

Off topic but is it me or do the fans in the rangers seem to protrude farther than most mech fans?

 

[Muffin1]

Well, I had a day.
While working on my daughters' boyfriends 2019 Ranger XLT, guess what I found.
A nice little broken hose, I played with it some as I wanted to compare his vs mine.
I noted allot of slop in the module as compared to mine.
Well, I ended up grabbing some extra 3/8 HP Fuel Line I had in my spare line box and added (2) clamps.
OEM Hose was deteriorated pretty badly and crumbled in my hand.

So, we can add another failure of the hose to the list.
I will have him monitor it.

Curious as to what the mileage is on his truck?

 

[airline tech]

Curious as to what the mileage is on his truck?

38,000, he bought it used about 6 months ago - I believe

 

[seasprite]

Well, I had a day.
While working on my daughters' boyfriends 2019 Ranger XLT, guess what I found.
A nice little broken hose, I played with it some as I wanted to compare his vs mine.
I noted allot of slop in the module as compared to mine.
Well, I ended up grabbing some extra 3/8 HP Fuel Line I had in my spare line box and added (2) clamps.
OEM Hose was deteriorated pretty badly and crumbled in my hand.

So, we can add another failure of the hose to the list.
I will have him monitor it.

To bad you couldn't wire in some kind of break away connector so if it fails it won't destroy the harness.

 

[Blue Streak]

38,000, he bought it used about 6 months ago - I believe

My 19 just turned 38,000. Doing some under hood checks the other day I gave special notice to this hose
Mine appears to be good as new, no signs of cracks or being brittle. Makes you wonder why some are bad & some are not. ?

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