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Flex A Lite Dual Electric Fans part #284

***-9-13-06 Update*** http://www.dieselplace.com/forum/showpost.php?p=1297205&postcount=216

Towing results here.

Update Tuesday June 6.
Quick Recap instead of reading through 12 pages...
Pro - did gain mileage. at least 2mpg city and at least 3mpg highway
Pro - loud scream of stock fan is gone along with no more drag on the motor
Pro - A/C does seem cooler
Pro - temps stay around 192 consistently and a little higher with A/C and at higher rpm
Pro - fairly easy install if you have some mechanical experience and some wiring experience.
Con - Fan clutch bolt was an #$%^&# to get off
Con - not too fond of the location of the TCM bracket
Con - power point hard to get to if you need it
Con - bolts for TCM bracket weren't included, but contacted them and they were sent to me later.
Con - *Update* noticed a hiccup while at a light with A/C on. Seems to be the A/C clutch cycling at the same time powering on and off the fans. I found out what this was and it was nothing related to these fans what so ever.
Con - if you have certain fuel pump upgrades the TCM will have to be mounted elsewhere. no location nailed down yet.


As I mentioned previously; installing these fans has nothing to do with any LLY overheating threads, posts, issues, fixes, and solutions. I don’t have an overheating problem. With that said I wanted less drag, less noise, same or better cooling, and possibly some gain in mileage. My LLY is my daily driver and the most I tow is a car trailer and variety of cars for a max of 8-10k for short highway trips, 100miles max and mostly flat to and from the track.

The label on the side shows all that is claimed to happen and please take notice of the fine print at the bottom..
NOTE: Electric Fans are not recommended for primary diesel engine cooling when the combined gross vehicle weight exceeds 18,000lbs (truck. trailer, and load) I my case, truck is 6500, car and trailer are usually no more than 5k. That is maybe 12k total.


Here is the kit. Purchased from Jegs as that was the best price I could find. Packaged and shipped with no issues. Twin fans, wires, brackets, controller. First inspection of the parts looks good and seems to have everything needed.


Here is the stock fan clutch and shroud as you all have seen.


Comparison of stock fans next to dual fans


Reverse side of clutch


Remove bottom dust shield to gain access to bottom shroud


Remove top and bottom shroud and TCM cover


Fan clutch with shroud removed


You’ll need a large crescent wrench or a 1.5” open end wrench along with a strap wrench or some other way to keep the water pump pulley stationary while you break loose the huge nut. I purchased 2 strap wrenches from Lowes for $20 and used the larger of the two to hold the pulley in place. I lodged it underneath the A/C compressor for leverage. This step alone took me 2 hours. That bolt would not budge. I soaked it with WD40, tried again along with several sharp hits with a hammer to the crescent wrench. Finally I beared down with legs in the air and it broke loose.


OEM fan and clutch removed, shroud removed..naked Duramax!!


Test fit of new fans driver and pass side shots



Fan is secured by supplied bolts using factory holes. Bolts are not tightened at this time to make sure all sides fit snug and foam is 50% compressed against radiator.


I mounted the control module on the side of the fuse box. It’s just a plastic cover shielding the fuses and all. It fits good and is close to power, ground, fuses, and battery.


Here shows the module in relation to the power, battery, A/C wire, etc.


When I went to mount the TCM to the bracket supplied I noticed there were no screws, bolts, or anything. The Instructions say to remove it from its cover and set aside, but there is no mention of it after that. I had to hunt down a bolt and nut while the top hole has two tie wraps temporarily. I was disappointed with this part.


The TCM mounted to the bracket also causes it to be a bit difficult to access the power point. The bracket is somewhat flexible and you can just move it briefly and open the power point, but I just wanted to note that it was too close in my opinion and could possibly cause issues if you ever had to use it to jump start someone. You don't want the cables to hit the TCM.


Here is the kit installed. I just need to get some wire loom and cover all the wires and it’s completely done. I followed the ignition instructions and it worked like a charm. I turned on the A/C and the fans came on. The fans come on at 60% when your operating temp is reached. If the temps get higher then the fans will kick on at 100%. There is also a 6 second start up delay so it won’t interfere with your starter and cause issues with charging/starting.


Here are a few more finished pictures.. you can see the TCM and how it fits and how close it is to the power point.




So far I have driven it about 2 miles and then it started pouring rain so I can home. I have to say the motor is much quieter and when the fans do come on you sort of think you hear the fans, but as you turn off things and roll the windows up they have already turned off. I let it idle for a good 30 minutes while it reached operating temps and once it hit 192 the fans came on briefly. I turned the screw back just a tad so the temp would get to 195.

I’ve always monitored my engine temps, EGT’s, mileage, etc. I run an Edge on level 4 for daily driving. Currently temps here when not raining are 90-100 degrees. My previous mileage is usually about 13-14 in the city, more on the highway.

I wasn’t real happy that the TCM was mentioned only for removal and no where else while there were no bolts included to mount the TCM to the new bracket included. It’s a small oversight, but if I didn’t have a neighbor around that took me to the hardware store I would have been highly upset. I just happened to block my car in the night before and without thinking started the install.

As far as telling it when to come on I want to make sure the engine temps reach at least 180 for the Edge to come on and keep the temps above that. The operation temp if I remember is 195. I’ll have to set it to come on when it reaches 196 and if it gets higher the fans will spin full speed.

Also I forgot to mention..while sitting in the cab I turned on all my lights, stereo, A/C and some other things. The amp meter moved a tick, but never missed a beat. I'll be watching the amp meter closely.

Having something to stand on to gain better access to the engine bay is almost a must have. I used my two car ramps on either side.
I will update this as I go along, but that is all for now.
 

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I also want to add an electric fan on my truck, but that is in addition to my engine driven fan. My fan engages alot when I come off a freeway and back to city streets for a few minutes and my engine temp will only be around 195 or so. My engine has never gone over 201 but I'd like to have my ponies back when the fan engages, so figure having both can't hurt. I figure my fan come on after a long time of alot of boost (such as towing big load at 75 on freeway) which is making the intercooler get hot and thats engaging fan. Hopefully electric would keep intercooler an little cooler and stop the fan from engaging.
 

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Do you feel the extra power?
 

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Discussion Starter #4
probably not feeling it right now, but wasn't expecting it either. We'll see how it goes.
 

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if anyone has any questions, wants other pictures, more data...just ask.

I plan on watching things closely from now on until I feel confident in it's ability.
 

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Be nice to get a dyno run of it with the same setup as the last one you did and see any difference in the curves or numbers. Any chance of that?
 

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Be nice to get a dyno run of it with the same setup as the last one you did and see any difference in the curves or numbers. Any chance of that?
only time would be a factor. I have access to 3 dyno's so I'll see what I can do. I'll do the same as I did before, stock and level 3 runs.
 

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i assume it would be hard to feel any extra power. would need a dyno to be certain, but what a waste of money and time to just see 10-20 hp. i can definitely tell the loss of power when my factory fan engages. it's also very loud. how do the electric fans compare when running at 100% are they quieter or have you not had them to 100% yet? tcm mounting problem, then there should be no problems with a manual trans. very nice write-up i must add! now just waiting for the fuel mileage increase (if any). thanks for the detailed info!
 

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Discussion Starter #9
they come on at 60% by default and I haven't had them at 100%, but all I have to do is turn the adjustment screw all the way and it will come on fully.

you can't feel it when the fans come on which I like nor can I feel any seat of the pants power freed up, but as stated this would hopefully show on the dyno.

as I said I'm happy with less sound, less drag, and mileage gains are a plus!!
 

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Thanks for sharing, I would think that the air conditioning would cool better.
I know on my old truck the only time I need to turn the electric fan on is when the exhaust temps are high or 90+ degree stop and go driving. Looking foward to your results
 

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Thanks for the write up. I'd was considering doing this as well. I look forward to seeing your dyno results.

That TCM mount turns me right off.. I'd have to do something different on my truck.
 

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Discussion Starter #12
I agree, I'm not too pleased with how/where it is mounted. It also is not covered which exposes it to heat as well. not sure what kind of affect that may have.
 

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I was actually just noticing this in the driveway. Typically my trans temps never went above 150 "that I noticed." Just now it showed just above 150, but below 200.

I got on it a few times earlier and couldn't really tell a seat of the pants difference, but I noticed the ECT went up to about 198, but then came down quickly to 192-195.

Maybe it's just me, but the truck seems to drive differently..the shifts seem different for some reason. Normal acceleration seems, for lack of better terms, lighter? easier?

At a stop you can just barely hear the fans, but you can hear them. As I said once before I wasn't sure if it was the fans or not because of how distant sounding it was, but it's WAY quieter than the OEM fan.
 

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It stands to reason that you will be gaining more power. You quite likely are seeing changed shifting due to the new found extra power. Same goes for feeling lighter.

What did you pay for the fans?
 

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Discussion Starter #16 (Edited)
through Jegs it was about 440 with free shipping. Everywhere else was 500+
 

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Briano, 1st GREAT write up and installed photos. Can't get better then that! I too had a Flex Lite Fan in my 83 Jeep CJ7 with a Chevy 350 Short Block. I noticed better power and milage. I installed a "cut-off" switch so when I did deep water crossings the fan wouldn't get damaged. I have nothing bad to say for the fan. I live in So Cal and wounder if it would help me. Looking foward to seeing more on this from you as you run it more.:cool2:
 

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Where does the temp sender go that the electric fans use?
Is it measuring radiator temp or engine water temp?
 

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Discussion Starter #19
D'oh!! the one thing I forgot to take a picture of. I'll get one.. the sensor goes in the fins of the radiator near the upper hose on the drivers side.

Also I contacted Flex A Lite telling them about the missing nuts and bolts for the TCM and also the instructions being less than accurate. I got a reply..he said the first units that went out did not have the nuts and bolts and also had instructions that were like mine. I asked him to send me the nuts and bolts and also a copy of the new instructions.

I also mentioned ot him about the TCM mounting location being right on the power point and that is not good for using it to jump another car battery because if the jumper cables hit the TCM and short out..you're screwed!

I'll post the reply when I get it.
 

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Nice job! I think you would want to run it 100 percent when on the dyno or at the track to give the intercooler all the help you can. Just the opposite of a cut-off switch, run a full on switch.
 
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