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Dodge Ram 2500 Flex-A-Lite Dual Electric Fan Kit - Four Wheeler Magazine

Ken Brubaker Senior Editor, Four Wheeler

There are 27 reasons why the owner of this Cummins-powered 2006 Dodge Ram 2500 wanted to switch from the stock engine-driven cooling fan to the Flex-A-Lite dual electric fan kit, and they all end in horsepower. Also beckoning the owner were 30 more lb-ft of torque and a 6-percent increase in fuel mileage.

The switch to the Flex-A-Lite system took the team at Attitude Performance about four hours, and everything is included for a painless swap.

PhotosView Slideshow <strong>1.</strong> Included with the kit are the new fan/shroud assembly, brackets, variable speed control, relay, wiring, hardware, and instructions. <strong>2.</strong> The instructions detail what factory components need to be removed, like the factory fan and shroud, so the Flex-A-Lite system can be installed. Removing these items requires working both above and below the engine bay. Flex-A-Lite notes that disconnecting the electric clutch on the factory fan may cause the vehicle's "check engine" light to illuminate after start-up. This happens because the vehicle's ECM is no longer receiving a signal from the electric clutch on the fan. Our "check engine" light didn't illuminate, but it did log a "soft code" into the vehicle's computer. <strong>3.</strong> The new Flex-A-Lite passenger-side bracket is then installed to the fan/shroud, and the assembly is slid into position behind the radiator and affixed with the two new brackets that are included, as well as factory hardware. PhotosView Slideshow <strong>4.</strong>A few electrical connections are then made, and the kit's instructions walk you through the process. The variable speed controller (VSC) wires directly to a "hot" circuit in the power distribution box (shown). This provides power to the new system. Another connection is to the wires going to the air conditioning (A/C) clutch. This connection tells the fans to turn on and cycle with the A/C clutch. <strong>5.</strong>This is the new temperature sensor, which monitors the coolant temperature. It simply inserts into the radiator fins near the inlet hose. The wires attach to the VSC per the instructions. <strong>6.</strong>Here you can see the completely installed system. The last step is to follow the initial start-up and adjustment procedures (yes, the VSC is adjustable). It's worth noting that when the vehicle is started, there's a 6-second delay in fan operation. This delay is to allow the starter to start the vehicle without the fan's drawing any power. In daily operation, the VSC triggers the fans at the set temperature at 60 percent. This reduces the load on the charging system. If the temperature rises by 10 degrees from the set point, the fans will be running at 100 percent.

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