Dodge Pickup Truck, Van & Motorhomes
The brackets provided with this kit are intended to mount the electric fan to the radiator. Due to the number of variances, we cannot guarantee that all the brackets necessary is included with this kit.
Variable Speed Control (VSC)
REMOVE EXISTING FAN & SHROUD ASSEMBLY:
1. Remove plastic radiator cover, and top half of fan shroud (some shrouds are a single piece).
2. Remove fan and clutch assembly. If clutch is mounted to pulley with four bolts, remove nuts, remove clutch/fan assembly and replace nuts. The clutch may be mounted by a large single nut. It may be possible to remove this clutch by fitting a large wrench to the nut. Put a rag over the fan to keep from being cut. Hold the fan in place and pull the wrench in the direction of rotation, it may help to give the end of the wrench a sharp strike from a soft-blow hammer to break the nut free without the pulley slipping.
3. Remove the lower shroud.
ELECTRIC FAN ASSEMBLY:
1. Look at the vehicle construction around the radiator for potential mounting points. Mounting
points for the fan serves two purposes, to carry the weight of the fan, and to hold the fan against
the radiator core. Cross braces, radiator trays, front facia, radiator-mounting points, are possible
mounting points for these brackets.
2. Whenever possible we do not recommend mounting brackets to the radiator core so that
the core carries the weight of the fan. In some applications this can cause damage to the
3. Locate at least four points to mount the fan to the vehicle that will support the weight and
secure the fan to the radiator.
MOUNT THE VARIABLE SPEED CONTROL (VSC)
1. Careful planning will save time. Look at the wires coming from the motors. The positives from each motor will be connected together, as will the negatives, with a two into one bullet connector. It may be easier to drill a hole through the center brace in the shroud to pass the wires through before attaching the bullet
2. Once the path for the motor wires has been determined, attach a blue bullet connector to each wire. Plug both red wires into a two into one bullet connector. Repeat for the black motor wires.
3. It is easiest to attach the Variable Speed Controller directly onto a corner of the shroud nearest the battery. The VSC may also be mounted any place that is easy for access. Once a location has been determined, secure the VSC with the 2 screws provided.
4. You may either drill one 3/8" or two 1/4" holes in the shroud where the 10 GA wire will pass through the shroud. This wire will connect the VSC to the two into one bullet connectors installed in step #2. Pass the 10 GA wire through the holes and crimp a bullet connector to each wire. Do not cut the 10 GA wire to
length until after the fans are installed. IMPORTANT: Plug the red 10 GA wire into the connector that has both red motor wires. Plug the black 10 GA wire into the connector that has both black motor wires. This will ensure that the fans spin the proper direction. Red motor wires positive. Black motor wires negative
5. Attach fan assembly to points located previously in "Electric Fan Assembly" instructions. Make sure fan seal is contacting radiator surface and is compressed 50%.
6. Determine length of 10 GA wire needed from step 4 to reach VSC. Trim both wires and attach female spade connectors to ends of each wire. Plug the red 10 GA wire onto terminal #3. Plug the black 10 GA wire onto terminal #2.
7. Attach spade connectors to theremaining 10 GA wire. Plug the
black 10 GA wire onto terminal #1. Plug the red 10 GA wire onto
terminal #4. Determine length of black wire needed to reach negative
terminal on battery and trim appropriately. Attach required
connector and connect to negative terminal on battery.
8. Locate fuse holder. Remove fuse and DO NOT INSTALL FUSE
UNTIL ALL WIRING IS COMPLETE. Attach required connector
to one side of fuse holder wire and attach to positive terminal on battery. Locate red 10 GA wire from step 7 connected to terminal #4 on VSC. Determine length needed, trim and attach with connector to
other wire from the fuse holder.
9. Find a circuit that is "hot ," preferably in a fuse box, when the key is
in the "ON" position. Attach the included fuse tap to fuse. Attach an
appropriate connector to one of the 14 GA wires included and connect
to fuse tap. Determine length of wire needed to reach VSC and trim to appropriate length. Attach spade connector to end of wire and
connect to terminal #9 on VSC.
10. Locate wires going to A/C clutch. Determine which wire is ground and which is positive. Determine if the clutch is activated by a positive or negative signal. Then attach supplied 14 GA wire by way of piggyback connector to the wire that activates clutch. If the wire is a positive signal, then attach wire to terminal #8. If it's a negative signal, then attach wire to terminal #7. Only one of the terminals will be used, not both.
11. Locate temperature probe. Remove plastic cap from probe and gently push probe through fins in radiator as close to the upper radiator hose as possible with 1/2"-3/4" of the probe protruding out of the front of the core. Re-install cap. This will give the VSC the most accurate engine temperature reading. Determine length of wire needed to reach VSC. IMPORTANT: Strip the insulation on the temperature probe wires
back about 1" and fold the wire on itself to effectively double the thickness of the wire before connecting spade connectors. Then attach these wires to terminals #10 & #11. Both wires need to be connected but it doesn't matter which wire goes to each terminal.
12. If manual switches (Flex-a-lite #31148) have been purchased, attach them as following. To override engine temperature to turn fans off, connect the switch to terminal #5 on VSC to send a ground signal. To override engine temperature to turn fans on, connect the switch to terminal #6 on the VSC so that a ground signal is sent.
13. Turn ignition on. After 5-6 seconds, LED #4 should light up. If not, check to make sure that you have 12 Volts at terminal #9 on VSC. The delay is to allow starter to start the vehicle without the fans drawing any power.
14. With your engine running, engage the A/C. Your fans should come on and cycle with the A/C clutch. LED's #1, 3 and 4 should be lit when fans are running. If they do not turn on, verify that the A/C clutch is engaged and make sure that you have the appropriate wire connected to correct terminal on the VSC. Shut off A/C and let engine continue to idle until you reach operating temperature.
15. Verify that operating temperature has been reached by feeling upper radiator hose. Hot water should be flowing through hose into the radiator. Adjust the screw on the VSC counterclockwise for a cooler setting or clockwise for a warmer setting. Once desired temperature is set, let engine continue to idle to make
sure the fans will cycle to maintain desired temperature. When fans are running, LED's #1 and 4 should be lit.
#8 AC Compressor Positive Signal
#9 Ignition Positive Signal
#10 Temp Sensor Positive
#11 Temp Sensor Negative
L1 Fan Signal
L2 Override Condition Signal
L3 AC Operation
L4 Ignition Signal
L2 L3 L4
#1 Battery Negative
#2 Negative to Fan
#3 Positive to Fan
#4 Positive Input from Battery
#5 Negative Override Signal OFF
#6 Negative Override Signal ON
#7 AC Compressor Negative Signal
The Variable Speed Control has new features.
When you set the on Temperature, the fans will come on at 60%; this reduces the load on your charging system. If the temperature rises, the fan speed will increase. If your set temperature is 185 degrees Fahrenheit, then between 185 and 195 the fan speed will increase from 60% to 100%. So after a 10-degree rise from the set point, the fans will be running at 100%.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E., Fife, WA 98424, Telephone No. 253-922-2700, warrants to the original purchasing user, that all Flex-a-lite products to be free of defects in material and
workmanship for a period of 365 days (1 year) from date of purchase. Flex-a-lite products failing within 365 days (1 year) from date of purchase may be returned to the factory through the point of
purchase, transportation charges prepaid. If, on inspection, cause of failure is determined to be defective material or workmanship and not by misuse, accidental or improper installation, Flex-a-lite will
replace the fan free of charge, transportation prepaid. Flex-a-lite will not be liable for incidental, progressive or consequential damages. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may have other rights, which vary from state to state.
The Flex-a-lite warranty is in compliance with the Magnuson-Moss Warranty Act of 1975.
rev. 10-06-05 part no. 99790 Page 1 of 2