Commonly misspoken as "clutch fan," a faulty fan clutch is an often overlooked cause of engine overheating, as the fan clutch helps regulate engine temperature. Both thermal and non-thermal fan clutches increase the rate of airflow across the engine's radiator by controlling the rate of spin of the engine's cooling fan. A thermal fan clutch operates via a temperature-sensitive spring, while a non-thermal responds to changes in engine RPM. To properly repair a faulty fan clutch, the unit must be replaced.
Place the bucket under the radiator. Open the radiator petcock with your fingers and drain the coolant from the system. If the petcock sticks, use the adjustable wrench to gain leverage.
Select the appropriate socket wrench and loosen the lower radiator hose clamp. Pull the hose free from the fitting and drain any remaining coolant into the bucket. Remove the upper radiator hose clamp with the wrench and pull the hose from its fitting.
Remove the bolts that attach the fan shroud to the radiator with a socket wrench. Slide the freed shroud back with your hands and allow it to rest on the spindle of the fan.
Loosen the bolt on the alternator tensioner bracket with a socket wrench. Rotate the alternator to release pressure on the fan belt.
Disconnect the two transmission cooling lines from the bottom of the radiator. Use the adjustable wrench for this. Pull the lines free from the radiator and drain the transmission fluid into the coffee can.
If the vehicle is equipped with a manual transmission, skip this step, as there will be no transmission cooling lines.
Remove the bolts from the two top and two bottom radiator mounting brackets with a socket wrench. Grasp the radiator with both hands, wiggle it free and remove it from the vehicle. Remove the fan shroud.
Remove the bolts that attach the fan clutch to the water pump with a socket wrench. Remove the fan-fan clutch assembly from the vehicle.
Remove the bolts that attach the fan clutch to the fan with a socket wrench and install the new fan-clutch in the same position. Tighten the bolts with the torque wrench to 6 to 8 foot-pounds of pressure.
Reinstall the fan-clutch assembly to the water pump and bolt it in place with the torque wrench to 6 to 8 foot-pounds or pressure.
Hang the fan shroud over the fan spindle. Set the radiator into the radiator mounting brackets and reattach the radiator with the bolts. Slide the fan shroud forward into place. Reattach it with the bolts.
Reattach the transmission cooling lines, if so equipped. Replace the upper and lower radiator hoses and secure in place with the hose clamps.
Move the alternator back into its original position, pulling the fan belt tight, and secure in place by tightening the tensioner bolt.
Refill the radiator with the drained coolant and replace the transmission fluid, if needed.
