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My pretty cool electrical fan conversion on my ZJ

Old 09-15-2013, 04:15 PM
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Default My pretty cool electrical fan conversion on my ZJ

I have found a few electric fan how to's, mostly for Taurus fans, but I kind of liked the Ford Contour dual fan setup I've seen. I thought I'd share my take. I won't be able to finish this in one sitting, but I can assure you, it works, and well. First, I found a 98, or 99 Ford Contour with the dual electric fan. Cost me about $45. There were 3 nuts holding it on, plus a ground wire, that I strongly suggest disconnecting rather than cutting. Had to cut a few wires, bend some A/C lines, but all in all, it was pretty easy to remove. Then I picked up a few electrical components and took it all home. I did all this with the radiator still in the ZJ, BTW. I took all the nuts holding the fan clutch to the pulley, then the two nuts at the top of the fan shroud, and removed the fan and shroud together.
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Here they are next to each other
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Old 09-15-2013, 04:19 PM
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Now of course, there will be extra wires to eliminate. I opened up all the wire looms to help, then replaced after I had the wires sorted. You'll only need three wires; the black ground I said to save, and two green wires that you can connect.
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Old 09-15-2013, 04:26 PM
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The tabs that were holding the fans to the Ford should be removed so it will fit, and after a few trial fittings, you can decide what else to remove. My tip; disconnect the top radiator hose. I found I needed to remove some material because it was hitting the steering box.
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It occurs to me that I didn't address the fan orientation. It has a box with a switch that serves no purpose after we've eliminated all the unnecessary wires, it should be at the top passenger side. That's where we'll be putting the thermostat control.
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Old 09-15-2013, 04:36 PM
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Now, I want this fan to be hands free, no brainer operation. I don't need a toggle switch that I can forget to switch on or off. I bought a thermostat switch to control the fan for about $17, and a relay to handle the power to the fan. I also wanted the fan to come on with the A/C, but I didn't want to add another relay just for that. I am using a diode to make the fan come on with the compressor, but keep the thermostat from cutting on the compressor. Confused yet? Here is the thermostat control and the diodes.
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Old 09-15-2013, 04:42 PM
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The fan shroud has a perfect place for the thermostat switch, I just had to drill a hole for the temp probe and cut a hole big enough to access the two terminals.
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Old 09-15-2013, 04:54 PM
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See? Fits pretty good!
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The bracket that comes with the thermostat kit works good at securing it, and the relay mounts to it as well!
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Old 09-15-2013, 04:59 PM
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I can start running wires at this point. I cut a small section of the blue wire from the kit to go from the thermostat to the relay, but I splice the remaining blue wire to the female that goes on the relay side. This will be the wire that goes to the compressor. I also connected the fan power to the relay per the wiring diagram.
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Old 09-15-2013, 05:02 PM
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I then cut the compressor wire, and solder the diode, covering with heat shrink tubing.
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Old 09-15-2013, 05:03 PM
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That's all for now, I'll try to post the rest tomorrow.
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Old 09-15-2013, 11:02 PM
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Keep us informed! I've been wanting to do a swap like this to my 95ZJ. I'm going to use a taraus fan,

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Old 09-16-2013, 07:45 AM
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Originally Posted by Bustedback View Post
Keep us informed! I've been wanting to do a swap like this to my 95ZJ.
I have to say, its working better than I expected. I can hold my hand to the front and actually FEEL the air being pulled in! The air conditioner runs colder at idle, and without the air conditioner running, it doesn't even come on when the Blue J is running down the road.
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Old 09-16-2013, 08:22 AM
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I looked on www.rockauto.com and found the whole fan assembly for less than a hundred bucks, not including shipping. I think I just might bite the bullet and get all of the needed stuff.
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Old 09-16-2013, 11:49 AM
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Excellent post!! This one should be archived! Your step-by-step was very informative and clear. The only thing I question is the load carrying capacity of that diode.
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Old 09-16-2013, 12:24 PM
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Originally Posted by dave1123 View Post
Excellent post!! This one should be archived! Your step-by-step was very informative and clear. The only thing I question is the load carrying capacity of that diode.
Since the wire's only load is the relay, the diode isn't really taxed. It is rated for 30 amps, I think, and the A/C circuit has a 25a fuse (if I remember).
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Old 09-16-2013, 12:49 PM
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You're right, I didn't think it thru. The only load is the relay command signal. My bad!
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