Fan Clutch Install
I'm dredging this up to (1) thank those in this thread for the instructions and (2) to summarize the steps that I used based on these posts:
1) If you live in a rust prone area, give the 4 nuts on the waterpump pulley a shot of PB Blaster for a few days
2) Make sure the truck is dead cold if you don't want to scald your hands and arms (remember, your clutch is shot, so the truck is running hot!)
3) Remove the two 12mm bolts that attach the upper part of the fan shroud to the rad
4) Carefully pull the fan shroud up to unseat the bottom of the shroud
5) Cut up the cardboard box CDan shipped the fan clutch and your other goodies into a flat cardboard sheet. Carefully insert the sheet behind the fan shroud to protect the rad fins from the fan, tools, etc.
6) Attach a 12mm wrench to the first of the 4 nuts on the water pump pulley (the four you can see aft of the fan). Lean on the belts to prevent the engine from turning over. Give the end of the wrench a tap with a hammer - this worked like a charm for me to start the nuts. The area is too confined to use a ratchet set, so gear wrenches are great in this case. As needed, let off the pressure on the belts to allow the engine to turn so you can access the bottom nut.
7) Slip the fan / fan clutch off of the four studs
8) Very carefully, push the fan shroud aft on the USPS and slowly bring the fan and clutch out. I found this to be fine, with lots of room (stock truck)
9) Give the 4 x 10mm nuts that hold the fan clutch to the fan a blast of PB Blaster
10) Use a low torque (eg 1/4" drive) 10mm socket to back off the four nuts, then pry the fan off the old clutch. Replace with new clutch and tighten the 4 nuts
11) Insert the fan and clutch back between the rad and the fan shroud.
12) Fit the clutch onto the four studs and press in to reseat the water pump pulley. Start the four nuts and tighten by hand. Alternate tightening the nuts with a wrench while pressing on the belts to keep the engine from turning over
13) Pull the carboard and reseat the bottom of the shroud. Reattach the two 12mm top shroud bolts
14) Give the fan a spin to make sure nothing is in the way and then fire it up to make sure everything looks and sounds ok
As you can see, no need to remove the shroud, rad, battery box, etc if you don't want to. Also, no need to take the belts off if you don't want to / aren't replacing them.
This took me ~45min in my driveway with two 4 year old 'helpers' (they spent most of the time pulling random tools and finding bugs under rocks) - and I've never done this before. It is a
job. I REALLY notice the difference - the fan BLOWS now - so I'm hoping this brings down the engine bay heat, which I've always found really hot.
I guess I'll get to test it out in my upcoming 4,000KM road trip!
Cheers, Hugh
