stickshiftsrule
05-13-2007, 10:55 PM
This weekend I installed the Flex-a-light kit I got from AIR_RAM.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_162_full.jpg
I removed my air intake system (MIT and stock airbox).
This made it easier to get the tanks off the radiator shroud and remove the shroud.
Then I removed the washer fluid/coolant overflow tanks. There are two bolts and large tabs at the bottom holding it in place.
There are two plugs, the one for the washer was tricky, you have to slide the red clip upwards.
Unplug the hoses to both tanks and drain off the winshield washer fluid.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_163_full.jpg
There are two bolts holding the fan shroud as well as two tabs down below.
The bolt on the driver's side is easier to get if you have a universal extension.
There is also a hose support on the driver's side bottom of the shroud.
It holds some hoses from underneath. From above, squeeze the "head" of it with some pliers and it will "pop" down and out of the shroud.
Now you can maneuver the shroud out of the engine bay.
Next comes the "fun" of getting the stock clutch fan off.......lol :crazy:
There are many ways of going about this, but here is what I did.
Two bolts of the right length that just barely fit through any two of the four holes in the waterpump pulley and bottom out against it......that way they catch the support webbing when you try to loosen the fan. I tried just one.......but it "cocked" too much and looked like something might break. One of the brackets from the kit and two bolts lined up to the pulley would have worked better now that I think of it.....DOH!
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_164_full.jpg
Odd how the stock fan looks.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_165_full.jpg
The fan is easy to mount.....too easy......I overthought the install and failed to see this at first because the directions are for an install NOT re-using the stock shroud.
The e-fan mounts inside the stock shroud towards the lower right.
Position both pieces in place (in truck) to get an idea of exactly where you want to position the fan inside the shroud.
Then take them back out, mark and drill, the holes for attaching the bottom and right side of the e-fan shroud to the stock shroud. You will be using the built in bolt holes on the e-fan.
Also, attach one of the two "large" brackets to the top of the e-fan shroud, this will add support up top as it perfectly fills the space up in that area.
Then use 4 bolts to attach the e-fan to the stock shroud.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_167_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_168_full.jpg
I also routed the fan wires out the side through a hole from my 1st attemt at lining things up...... :D
The wiring diagram in the kit is accurate. Wire as directed. Don't forget the probe, and that it needs to be near the upper radiator hose but clear of the e-fans shroud.
Only concern I have is that I hooked the 2nd smaller red wire to the battery (positive) (as well as the large red wire). I'm no electrician, and had no idea where to tap into.
So I left that wire long (looped up) in case someone gives me a better idea.
But, I tried shutting the truck off while the fan was running.....and it (the fan) didn't run very long afterwards.
Mounted the controller on top of the stock shroud......not crazy about it....but could not come up with a better spot....and wire-tied everthing off.
Re-installed washer/overflow tanks and air intake, as well as the hose support that clips under the shroud.
Once it's all wired up...started and warming up....you can set the contoller temp setting (dial/knob) using the temp guage on the truck.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_169_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_170_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_171_full.jpg
....My 1st wtite-up.....probably missed a few things you want answered....so feel free to ask/make suggestions.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_162_full.jpg
I removed my air intake system (MIT and stock airbox).
This made it easier to get the tanks off the radiator shroud and remove the shroud.
Then I removed the washer fluid/coolant overflow tanks. There are two bolts and large tabs at the bottom holding it in place.
There are two plugs, the one for the washer was tricky, you have to slide the red clip upwards.
Unplug the hoses to both tanks and drain off the winshield washer fluid.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_163_full.jpg
There are two bolts holding the fan shroud as well as two tabs down below.
The bolt on the driver's side is easier to get if you have a universal extension.
There is also a hose support on the driver's side bottom of the shroud.
It holds some hoses from underneath. From above, squeeze the "head" of it with some pliers and it will "pop" down and out of the shroud.
Now you can maneuver the shroud out of the engine bay.
Next comes the "fun" of getting the stock clutch fan off.......lol :crazy:
There are many ways of going about this, but here is what I did.
Two bolts of the right length that just barely fit through any two of the four holes in the waterpump pulley and bottom out against it......that way they catch the support webbing when you try to loosen the fan. I tried just one.......but it "cocked" too much and looked like something might break. One of the brackets from the kit and two bolts lined up to the pulley would have worked better now that I think of it.....DOH!
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_164_full.jpg
Odd how the stock fan looks.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_165_full.jpg
The fan is easy to mount.....too easy......I overthought the install and failed to see this at first because the directions are for an install NOT re-using the stock shroud.
The e-fan mounts inside the stock shroud towards the lower right.
Position both pieces in place (in truck) to get an idea of exactly where you want to position the fan inside the shroud.
Then take them back out, mark and drill, the holes for attaching the bottom and right side of the e-fan shroud to the stock shroud. You will be using the built in bolt holes on the e-fan.
Also, attach one of the two "large" brackets to the top of the e-fan shroud, this will add support up top as it perfectly fills the space up in that area.
Then use 4 bolts to attach the e-fan to the stock shroud.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_167_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_168_full.jpg
I also routed the fan wires out the side through a hole from my 1st attemt at lining things up...... :D
The wiring diagram in the kit is accurate. Wire as directed. Don't forget the probe, and that it needs to be near the upper radiator hose but clear of the e-fans shroud.
Only concern I have is that I hooked the 2nd smaller red wire to the battery (positive) (as well as the large red wire). I'm no electrician, and had no idea where to tap into.
So I left that wire long (looped up) in case someone gives me a better idea.
But, I tried shutting the truck off while the fan was running.....and it (the fan) didn't run very long afterwards.
Mounted the controller on top of the stock shroud......not crazy about it....but could not come up with a better spot....and wire-tied everthing off.
Re-installed washer/overflow tanks and air intake, as well as the hose support that clips under the shroud.
Once it's all wired up...started and warming up....you can set the contoller temp setting (dial/knob) using the temp guage on the truck.
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_169_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_170_full.jpg
http://memimage.cardomain.net/member_images/6/web/858000-858999/858912_171_full.jpg
....My 1st wtite-up.....probably missed a few things you want answered....so feel free to ask/make suggestions.