Electric Fan Conversion

RockenAlex

New member
Now, I do know this has been asked many many times, about e-fan conversions. Thing is no one really has a decisive answer. I used the 3rd gen specific thread search and sifted through everything I could find. There's flex-lite kits that get praised and trashed right and left, but it's enough so that I've just decided to stay away. There's a similar Jegs universal kit which is not ideal but hopefully the quality isn't as bad. There's also the Taurus e-fan mod that I couldn't find a decent write up here on, but did sound mildly promising. Then I stumbled upon this while looking through:

Toyota 4Runner Electric Cooling Fan Kit More MPG HP | eBay

Its a company called FF dynamics who seem to make quality fan shrouds and kits for many different vehicles and have 3rd gen specific kit on ebay (link above^) but not listed on their website. They also have an "extreme duty" section that does not have a Toyota listed but most of the sections do say something along the lines of if you have an high performance vehicle ask about our extreme fan setups. I've messaged the seller be they haven't gotten back to me.

If anyone has any good experience with our runners they'd like to share it would be much appreciated. Also I haven't looked into their fan and electronics source yet. But here's the pic they advertise for reference, I do not know if any of those are the runner kits.
 

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Are you swapping to a V8 or something? These trucks have excellent cooling systems from the factory. If you are overheating you have a cooling systems problem that needs fixing. I'm not hesitant at all to use an electric fan if needed, but I've never gotten over about 205 deg even when crawling on the hottest days or sitting in traffic at 100 deg (the only times you need the fan). The only way you will get any more MPG or horsepower from going to an electric fan is if your fan clutch is bad and the fan is spinning all the time (it takes power to make the electricity to run the electric fan too). The factory clutch fan disengages at highway speeds (or even around town) when it is not needed (to save gas and make more power).

All of the ebay seller's claims are bogus:

LETS CHECK OUT THE BENEFITS

1. YOU WILL GET MORE MILES TO THE GALLON OF GAS - NOT - it takes power turn an electric fan, probably more than the factory fan.
2. MORE REAL HORSEPOWER THAT YOU WILL FEEL FIRST TEST DRIVE. - NOT - Only if you disconnect the alternator and run the fan from the battery like the drag racers do, and even then, maybe 1 or 2 HP at the most (you won't feel that).
3. MUCH COLDER AIR CONDITIONING THEN EVER BEFORE - NOT (unless MAYBE sitting in traffic at 100 deg)
4. NO MORE NOISEY FAN NOISE FROM UNDER THE HOOD - NOT (the electric fan makes no noise? My factory fan makes no noise I can hear. The Taurus fan in my 65 Mustang sounded like an F-16 when it was running on high.)
5. MUCH FASTER ENGINE WARMUP - MUCH FASTER HEAT IN THE WINTER - NOT - the clutch fan is not engaged when the engine is cold
6. THE ABILITY TO CONTROL YOUR ENGINE TEMP FOR MAX POWER - NOT - you won't get any more power by keeping the engine cooler, only more wear and less mileage, IF it would even keep it cooler - the thermostat will regulate the minimum temperature, not the fan
7. SAVE ABOUT 15 LBS OF WEIGHT OFF THE FRONT END - NOT - This fan and shroud will weigh LESS than the factory fan, which is about 5 lbs?
8. NO MORE WATER PUMP FAILURES, WATER PUMP LIFE IS EXTENDED 3 FOLD - NOT - the fan has nothing to do with the water pump, which is driven off the timing belt
9. YOUR 4RUNNER WILL RUN COOLER THEN IT EVER HAS EVEN IN SUMMER MONTHS - NOT - if it is not running cool enough you have cooling system problems to repair. An electric fan won't fix them.
10. ENGINE WILL RUN NOTICABLY SMOOTHER AND THROTTLE RESPONSE WILL BE QUICKER - NOT ???? That claim isn't even worth an answer ????

I sure wouldn't spend almost $300 (with shipping) for a setup that won't gain anything, will almost certainly be less reliable than the factory setup, and comes from a seller who flat out lies about the benefits of his product (or knows nothing about cooling systems and engines).
 
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Yes... A 4.7 swap is in the works. I also run through a lot of deep water so my stock fan hits it and flings the muddy water every where. I somehow grenaded one fan already and luckily found a replacement the next day. Don't want to do that again so I was exploring my options.
 
Ive ran electric fans on some different cars and they never push the same amount of air. To stop overheating when running my talon hard I had to add 4 fans, push and pulling and got the highest CFM I could. THe stock fans pushed so much more air. Look at the size of the stock fan blades compared to the tiny slim line fans. I would stick with stock cooling and fan as much as you can. But if you swapping to a v8 you have no choice. Not sure why your asking then. If you cant fit stock fans with the v8 swap you will have to go with slim lines and deal with there horrible performance.
 
Yes... A 4.7 swap is in the works. I also run through a lot of deep water so my stock fan hits it and flings the muddy water every where. I somehow grenaded one fan already and luckily found a replacement the next day. Don't want to do that again so I was exploring my options.

The Taurus fan is a great fan, but it pulls about 40 amps on high speed (it will suck small animals through the radiator!). You'll need a heavier alternator than the 80-amp one on the 4Runner. It's also pretty deep (5" if I remember right). If you can make it fit, you won't be disappointed. I found one at the salvage yard for $35 (I think, from a 95 Taurus) and put a new motor in it ($90). I modded the shroud to fit the radiator (it's plastic so easy to mod). It worked great in my 65 Mustang (4.6L supercharged - 550HP). Never got hot - ever.
 
5. MUCH FASTER ENGINE WARMUP - MUCH FASTER HEAT IN THE WINTER - NOT - the clutch fan is not engaged when the engine is cold

Idk about you, but every vehicle I have owned has had the fan run when I started it in the winter and it continues to run while idling so his statement is somewhat true. (doesn't really matter until thermostat opens)
 
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The Taurus fan is a great fan, but it pulls about 40 amps on high speed (it will suck small animals through the radiator!). You'll need a heavier alternator than the 80-amp one on the 4Runner. It's also pretty deep (5" if I remember right). If you can make it fit, you won't be disappointed. I found one at the salvage yard for $35 (I think, from a 95 Taurus) and put a new motor in it ($90). I modded the shroud to fit the radiator (it's plastic so easy to mod). It worked great in my 65 Mustang (4.6L supercharged - 550HP). Never got hot - ever.


I ave a CS130 on there already, it's 100amp at idle from what I remember. Think that would be enough to keep up with the Taurus.

Here's a Taurus fan on ebay this what I should be looking for?
1992 1995 Ford Taurus Cooling Fan 92 93 94 95 | eBay
 
I ave a CS130 on there already, it's 100amp at idle from what I remember. Think that would be enough to keep up with the Taurus.

Here's a Taurus fan on ebay this what I should be looking for?
1992 1995 Ford Taurus Cooling Fan 92 93 94 95 | eBay

My Mustang had a 130 amp alternator and it did fine. The CS130 should do okay. That is the fan, but you can find it cheaper. I'd check the dimensions (link here: Search for FORD TAURUS 620 101 in Radiator Fan Motors And Assemblies from DORMAN OE SOLUTIONS - Discountautoparts.com | www.discountautoparts.com/)

Amazon has it for $80 (Amazon.com: TYC 620640 Ford/Mercury Replacement Radiator/Condenser Cooling Fan Assembly: Automotive). Summit has the Dorman for $112. (http://www.summitracing.com/parts/rnb-620-101)
 
I have a taurus fan because I bought it cheap off a friend who bought and never installed it. It's coupled with a SPAL fan controller. I'm happy with the install, it is on low variable speed automatically by the controller, and then I have it switching to high by manual switch. I've never needed the high to keep things at stock temps. The fan shroud was easily modified to fit the fan, just heated up the plastic and shaped it to fit the taurus shroud.

My take on it:
  • It's much quieter than stock on low
  • My 4runner heats up at idle in just a few minutes no matter what the temp
  • It was expensive all said and done, and has no payback but then again no mods do
  • The fan does not draw 40 amps on high, that must be a start up draw. I was concerned about it but when measuring it later I believe it was about 20 amps on high.
 
[*]The fan does not draw 40 amps on high, that must be a start up draw. I was concerned about it but when measuring it later I believe it was about 20 amps on high.
[/LIST]

I stand corrected. I read a couple of posts on Ford forums where guys tested (and a youtube) and it pulled 20 on low and about 30 on high, with a startup spike of over 100. One test showed 34 amps on high. The current draw would vary with the amount of airflow restrictions (it takes more current to draw a given amount of air through restricted path). Still a lot of current (on high) for a stock 4Runner alternator. I agree that running it on low would be the way to go. On high, the Taurus fan pulls much more air than needed to cool a V6 4Runner (and probably a V8 as well - the V8 4th gens use a clutch fan and radiator about the size of ours), but if you had a switch to turn on high speed when needed, it would be nice (if you ever needed it).
 
Yes... A 4.7 swap is in the works. I also run through a lot of deep water so my stock fan hits it and flings the muddy water every where. I somehow grenaded one fan already and luckily found a replacement the next day. Don't want to do that again so I was exploring my options.

The water crossings are a legitimate reason to want an electric fan. That said I think most failures of electric fan conversion have more to do with the shrouding than anything. OEMs spend a lot of money to ensure proper airflow,even with relatively low cfm capability. I spend a lot of money and a lot of time trying to use electric fans and failed. I might do better today than I did 20 years ago, but the reality is I wouldn't even try. I'll be curious to see if you are able to get good daily driver use once you complete the conversion.

:snacker:
 
Idk about you, but every vehicle I have owned has had the fan run when I started it in the winter and it continues to run while idling so his statement is somewhat true. (doesn't really matter until thermostat opens)

There's a difference though between the fan spinning from the fan clutch being engaged and spinning just from residual friction.
 
Are you swapping to a V8 or something? These trucks have excellent cooling systems from the factory. If you are overheating you have a cooling systems problem that needs fixing. I'm not hesitant at all to use an electric fan if needed, but I've never gotten over about 205 deg even when crawling on the hottest days or sitting in traffic at 100 deg (the only times you need the fan). The only way you will get any more MPG or horsepower from going to an electric fan is if your fan clutch is bad and the fan is spinning all the time (it takes power to make the electricity to run the electric fan too). The factory clutch fan disengages at highway speeds (or even around town) when it is not needed (to save gas and make more power).

All of the ebay seller's claims are bogus:

LETS CHECK OUT THE BENEFITS

1. YOU WILL GET MORE MILES TO THE GALLON OF GAS - NOT - it takes power turn an electric fan, probably more than the factory fan.
2. MORE REAL HORSEPOWER THAT YOU WILL FEEL FIRST TEST DRIVE. - NOT - Only if you disconnect the alternator and run the fan from the battery like the drag racers do, and even then, maybe 1 or 2 HP at the most (you won't feel that).
3. MUCH COLDER AIR CONDITIONING THEN EVER BEFORE - NOT (unless MAYBE sitting in traffic at 100 deg)
4. NO MORE NOISEY FAN NOISE FROM UNDER THE HOOD - NOT (the electric fan makes no noise? My factory fan makes no noise I can hear. The Taurus fan in my 65 Mustang sounded like an F-16 when it was running on high.)
5. MUCH FASTER ENGINE WARMUP - MUCH FASTER HEAT IN THE WINTER - NOT - the clutch fan is not engaged when the engine is cold
6. THE ABILITY TO CONTROL YOUR ENGINE TEMP FOR MAX POWER - NOT - you won't get any more power by keeping the engine cooler, only more wear and less mileage, IF it would even keep it cooler - the thermostat will regulate the minimum temperature, not the fan
7. SAVE ABOUT 15 LBS OF WEIGHT OFF THE FRONT END - NOT - This fan and shroud will weigh LESS than the factory fan, which is about 5 lbs?
8. NO MORE WATER PUMP FAILURES, WATER PUMP LIFE IS EXTENDED 3 FOLD - NOT - the fan has nothing to do with the water pump, which is driven off the timing belt
9. YOUR 4RUNNER WILL RUN COOLER THEN IT EVER HAS EVEN IN SUMMER MONTHS - NOT - if it is not running cool enough you have cooling system problems to repair. An electric fan won't fix them.
10. ENGINE WILL RUN NOTICABLY SMOOTHER AND THROTTLE RESPONSE WILL BE QUICKER - NOT ???? That claim isn't even worth an answer ????

I sure wouldn't spend almost $300 (with shipping) for a setup that won't gain anything, will almost certainly be less reliable than the factory setup, and comes from a seller who flat out lies about the benefits of his product (or knows nothing about cooling systems and engines).


There's a TON of misinformation in this post. The factory fan clutch never fully engages. Even at highway speeds. The fan is ALWAYS spinning. An electric fan will ABSOLUTELY increase highway MPG and power. The amount of the increase is debatable, but there WILL be an increase. There are good reasons that damn near every modern vehicle sold uses electric fans instead of the clutch fan setup on our trucks. The blade designs are much more efficient than what's on our trucks, and they can be positioned closer to the radiator and shrouded more closely. They can also be more easily controlled to only run when needed.

1 - True
2 - True
3 - True (the clutch fan activates based on heat, not whether the A/C is on or not)
4 - Depends on the fans used and the fan controller, but it's going to be quieter for sure with the right controller
5 - True. The clutch fan is ALWAYS pulling air through the radiator, even when it's cold
6 - True, but the benefits are debatable


One test showed 34 amps on high. The current draw would vary with the amount of airflow restrictions (it takes more current to draw a given amount of air through restricted path). ).

This isn't really true either. Current draw on a axial fan is based on a curve. When you're operating the fan within the static pressure range it's designed for the current draw will be proportional to the amount of work being done (air being moved). Increasing the restriction reduces flow and decreases current draw. That seems counter intuitive, but centrifugal pumps work the same way. If you dead head them the current draw drops way off compared to running them where they're designed to run.

OP, the fans pictured are re-labled SPAL fans. I used to sell them in 24V versions for marine applications. Most of them are made in Italy as far as I know (haven't dealt with them directly in a couple of years) They're good quality fans.

If I were going to convert to electric I'd go with a pair of fans, and a simple relay based controller that will run them at half speed or full speed. There are some nice PWM controllers out there but I'm leery of the durability over the long haul.

The relay controllers work a lot like DRLs, by putting the two fans in series with each other. It's very efficient, and the current draw drops to about half of what one fan will pull on high. The noise drops dramatically. The current draw will vary depending on the fan, but the 11" 12V version we used to sell would pull just under 20amps. The 9" versions were around 12amps.
 
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PT Cruiser fans work pretty good. I ran one on my buggy in my avatar. I did burn up my relay and realized that it needed a number 10 wire ran to it. It cooled it really good and the built in shroud fit the radiator pretty good.
 
I have a Taurus fan because I bought it cheap off a friend who bought and never installed it. It's coupled with a SPAL fan controller. I'm happy with the install, it is on low variable speed automatically by the controller, and then I have it switching to high by manual switch. I've never needed the high to keep things at stock temps. The fan shroud was easily modified to fit the fan, just heated up the plastic and shaped it to fit the Taurus shroud.

My take on it:
  • It's much quieter than stock on low
  • My 4runner heats up at idle in just a few minutes no matter what the temp
  • It was expensive all said and done, and has no payback but then again no mods do
  • The fan does not draw 40 amps on high, that must be a start up draw. I was concerned about it but when measuring it later I believe it was about 20 amps on high.

Thanks for your response, is there any way you could shed some light on your setup or where I can get info on the one you may have copied. I'm interested in the heating the shroud and wiring part. I can do any kind of heating a reforming but I'm sub-par at wiring.
 
There's a TON of misinformation in this post. The factory fan clutch never fully engages. Even at highway speeds. The fan is ALWAYS spinning. An electric fan will ABSOLUTELY increase highway MPG and power. The amount of the increase is debatable, but there WILL be an increase. There are good reasons that damn near every modern vehicle sold uses electric fans instead of the clutch fan setup on our trucks. The blade designs are much more efficient than what's on our trucks, and they can be positioned closer to the radiator and shrouded more closely. They can also be more easily controlled to only run when needed.

1 - True
2 - True
3 - True (the clutch fan activates based on heat, not whether the A/C is on or not)
4 - Depends on the fans used and the fan controller, but it's going to be quieter for sure with the right controller
5 - True. The clutch fan is ALWAYS pulling air through the radiator, even when it's cold
6 - True, but the benefits are debatable




This isn't really true either. Current draw on a axial fan is based on a curve. When you're operating the fan within the static pressure range it's designed for the current draw will be proportional to the amount of work being done (air being moved). Increasing the restriction reduces flow and decreases current draw. That seems counter intuitive, but centrifugal pumps work the same way. If you dead head them the current draw drops way off compared to running them where they're designed to run.

OP, the fans pictured are re-labled SPAL fans. I used to sell them in 24V versions for marine applications. Most of them are made in Italy as far as I know (haven't dealt with them directly in a couple of years) They're good quality fans.

If I were going to convert to electric I'd go with a pair of fans, and a simple relay based controller that will run them at half speed or full speed. There are some nice PWM controllers out there but I'm leery of the durability over the long haul.

The relay controllers work a lot like DRLs, by putting the two fans in series with each other. It's very efficient, and the current draw drops to about half of what one fan will pull on high. The noise drops dramatically. The current draw will vary depending on the fan, but the 11" 12V version we used to sell would pull just under 20amps. The 9" versions were around 12amps.

I'm not disputing his claims either. I do believe the increase in efficiency especially since I already have a larger alternator. The price point is the only thing cautioning me away because that's a lot of money for something that could fail on me. So for $80 I'll risk needing to replace the Taurus fan.

And thank you for you great insight! I may go with those fans depending on what the seller says about the 3rd gen kit.
 
3 - True (the clutch fan activates based on heat, not whether the A/C is on or not)

The fan clutch is engaged on just about any AC equipped vehicle once you switch the selector to AC or Defrost. There's an override for this, regardless of the temperature. This is done to dry the air in defrost mode and to help prevent overheating in AC mode.
 
I'm interested in the heating the shroud and wiring part. I can do any kind of heating a reforming but I'm sub-par at wiring.

Here is what I had for pictures when I did it. When I held them together, the taurus fan fit right in the stock fan hole. I lined it up so the top two places I bolted it were flat and bolted it together. The bottom two holes as shown below involved simply heating the stock shroud until I could push the taurus fan into it so it would sit flat against the radiator.

As for the wiring, I wired the SPAL controller based on it's manual connected to the low fan wires. Then for the high, I used a toggle switch with two relays to completely disconnect the SPAL ground/positive from the fan and then the toggle switch completes the fan circuit. The reason for this was a complication with having the high and low circuits both connected and no two speed controllers out there.


Fan size comparison


Taurus fan behind stock shroud. Notched the edge where I was going to heat it on the part of the shroud that has a deeper lip.


Formed to fit the fan


Installed
 

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