Replaced Fan Clutch Wire Support Tube - Details / How To

[airline tech]

You also have this option from @TJC

Grind the end off of the support and (Tap & Install) a button head screw to get rid of the sharp edges on it - that appear to play a partial role in the hose splitting this puts a rounded edge on the end of the support.

Ref:

It has happened to me! (Dreaded Fan Sensor - Crumbling Hose!) | Page 11 | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

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[Stevedbvik1]

You also have this option from @TJC

Grind the end off of the support and (Tap & Install) a button head screw to get rid of the sharp edges on it - that appear to play a partial role in the hose splitting this puts a rounded edge on the end of the support.

Ref:

It has happened to me! (Dreaded Fan Sensor - Crumbling Hose!) | Page 11 | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

I took my dremel and chamfered the sharp edges of the nub.

 

[GreyAreaRanger]

What exactly is the purpose of this hose? From my understanding, it somehow prevents the fan clutch from spinning? If so, why not replace it with a steel support bracket?

 

[got3fords]

What exactly is the purpose of this hose? From my understanding, it somehow prevents the fan clutch from spinning? If so, why not replace it with a steel support bracket?

That is the greatest mystery of mankind.

 

[got3fords]

Grind the end off of the support and (Tap & Install) a button head screw to get rid of the sharp edges on it - that appear to play a partial role in the hose splitting this puts a rounded edge on the end of the support.

Seems like over kill to do both.

 

[RangerBill]

What exactly is the purpose of this hose? From my understanding, it somehow prevents the fan clutch from spinning? If so, why not replace it with a steel support bracket?

It needs to flex to allow for runout of the fan rotating sensor. A steel bracket would cause side pressure on the sensor and damage it.

 

[GreyAreaRanger]

It needs to flex to allow for runout of the fan rotating sensor. A steel bracket would cause side pressure on the sensor and damage it.

It still seems like a bad design either way. It is almost like they hope it goes bad to make extra money.

 

[twk]

Since I've read the many threads on this, I've been working on a way to replace that hose with a good, solid, damper. I'm sorry to say that I have no ideas so far...

 

[GreyAreaRanger]

Since I've read the many threads on this, I've been working on a way to replace that hose with a good, solid, damper. I'm sorry to say that I have no ideas so far...

Well, Ford apparently has electric fans for some 2024 models with the 2.3, like the Mustang. I bet it won't be too long until someone figures out how to rig them to these 5th gens.

 

[TJC]

Since I've read the many threads on this, I've been working on a way to replace that hose with a good, solid, damper. I'm sorry to say that I have no ideas so far...

I used a silicone hose with a 90- degree bend and inserted a 1/4" section of soft copper tubing into the center section of the hose, leaving both ends flexible. I then formed the hose to the same shape as the original by bending the copper tubing infused hose.

This copper tubing gives the hose strength across the bridge while still allowing the hose to flex when under load as the clutch cycles on and off.

It was more expensive to do, but I am more comfortable with this option over fuel line. My goal was to put the least amount of pressure on the sensor to keep wear to a minimum.

My solution may be overkill. Time will tell. But I am comfortable with it, and that is what counts. Peace of mind has intrinsic value.

 

[twk]

Well, Ford apparently has electric fans for some 2024 models with the 2.3, like the Mustang. I bet it won't be too long until someone figures out how to rig them to these 5th gens.

Yeah. How is this done on a mustang and F-150?
Same engine, different fan clutch set up I'm guessing.
I won't have time to check into this until much later today.

When the time comes, I thought I'd do something like quangdog did. A piece of hose with a natural curve, that is close enough to support the wires. Seems simple and easy enough.

Edit...
I see a quick check shows the Mustang has the fan(s) mounted on a frame, against the radiator. Why didn't we get a mount like that?

 

[Blue Streak]

Mechanical fan clutches have bee around for a long time. Back in the day when a fan clutch was going bad ( most of the time)you would have an overheating problem. If it went undetected then it would let loose & destroy the radiator. I have seen many working in that field. Today ours just destroys a bunch of important wires. Smart idea not. ?

 

[GreyAreaRanger]

Yeah. How is this done on a mustang and F-150?
Same engine, different fan clutch set up I'm guessing.
I won't have time to check into this until much later today.

When the time comes, I thought I'd do something like quangdog did. A piece of hose with a natural curve, that is close enough to support the wires. Seems simple and easy enough.

Edit...
I see a quick check shows the Mustang has the fan(s) mounted on a frame, against the radiator. Why didn't we get a mount like that?

I didn't see this until after your edit but that was going to be my guess. I am not sure what all is involved with it but I am sure someone will be determined enough to do it.

 

[Stevedbvik1]

Yeah. How is this done on a mustang and F-150?
Same engine, different fan clutch set up I'm guessing.
I won't have time to check into this until much later today.

When the time comes, I thought I'd do something like quangdog did. A piece of hose with a natural curve, that is close enough to support the wires. Seems simple and easy enough.

Edit...
I see a quick check shows the Mustang has the fan(s) mounted on a frame, against the radiator. Why didn't we get a mount like that?

Because the fan clutch in the Ranger 5G is a viscous modulating clutch. The PCM controls the fan speed dependant on various engine inputs. So the fan is not an on off setup like an electric fan would be. The problem would be that there’s no proper input from the PCM to control an electric fan.

 

[airline tech]

Basics the swap would need.

Using the 24 Ranger 2.3 (Wiring Diagram) for Cooling Fan Control

1. A dual fan assembly and a way to mount the assembly
2. (2ea) relays added and wired in to power the fans with 80-Amp fused power, so the addition of a fuse block and a relay center.
3. A separate fuse for (Relay Coil) Power 20-Amp
4. Reprogram the PCM to change it from pulsing ground to the clutch (fan) to the dual fan set-up.
The fans would have to have a controller incorporated into them.
5. The (Various Inputs) - Engine Temp, AC Clutch etc would already be in the PCM

Reprograming the PCM would be the biggest hurdle with this.
As both fans would always be HOT and running, but the PCM & Fan Controller would be controlling the speed they are turning

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