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2006 Dodge Ram 3500 Diesel Cooling Fan Hits the Fan Clutch Wires


Pjcrews

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Everytime I hit a little deep water, id say 2.5', the clutch fan hits the wires and tube they are encased in for the electric clutch fan. It destroys the clutch fan plus sometimes screws the ac compressor up. This is the 4th time and I am sick of this piss poor design. I have the tube bolted where its supposed to be. Is there a fix for this can I use the old style fan clutch that is not electric? Please help. Thanks

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Hi, Pjcrews, and thanks for posting this topic.  There may be an aftermarket non-electric (viscous or thermostatically controlled) replacement fan clutch that would eliminate the issue.  We can look into that solution.

 

Meanwhile, can you post a few pictures of the issue?  I'd like to see what's happening here.  There may be a way to improve the wiring layout.  Waterproofing in itself is a challenge.  I'd like to see how this tube or the wiring harness winds up interfering with the fan clutch and the A/C wiring.

 

Moses

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Pjcrews...I followed your link and made a copy of the electronically controlled fan.  When you want to attach photos, click on the "More Reply Options" below the editor box (right side).  You'll then have access to the "Attach Files" button (left side below editor box).  Your files (.jpg photo, PDF, whatever) will upload once selected.  You can then post the image or file wherever you place the cursor in the editor box.  It will become clearer as you try this function.

 

post-1-0-79010700-1408218822_thumb.jpg

 

I also made a PDF of our fan clutch service procedures, which you likely have memorized by now!  One of the key notes in the service guide is reference to DTC codes.  If you disconnect the electronic fan clutch, that circuit will likely send a DTC code and trigger an engine check light or "MIL".  This could be a nuisance if you were to attempt a clutch swap with a thermal viscous (non-electronic) fan clutch.  Here is the factory (2005-2006 coverage) manual section devoted to the 5.9L diesel's electronically controlled fan:

 

Electronic Fan Clutch Ram Diesel.pdf

 

Derale and others make fan clutches for the Ram Cummins diesel 5.9L.  However, the Derale mechanical (thermostatic) fan listing is for 2000-2003 model year.  You might call the Derale tech line.  Here's the website address:  http://www.derale.com.  Ask about retrofitting a fully mechanical clutch unit like their thermostatic type, and clarify what to do with the existing wiring and plugs regarding DTC codes.  Derale likely has been over this road with other Cummins owners. 

 

At Summit Racing, here is the listing for the Derale fan clutch for the 5.9L diesel (presumed to be 2000-2003 models):  http://www.summitracing.com/parts/der-22616/overview/.  There is also a Hayden electronic fan clutch available at Summit:  http://www.summitracing.com/parts/hda-3281/applications/.  This #3281, according to the Hayden website catalog, is for models up to 2004.  '05 up models like ours use the Hayden #3282.  You might want to see if the Hayden #3282 fan clutch (designated as an OE replacement) has better wiring and reinforcement of the wires.  Here's the Hayden catalog, see the Dodge Ram 3500 fan clutch listings:

 

 http://www.haydenauto.com/upload/HaydenAuto/Documents/Cat_Hayden/2013_HaydenCatalog_FINAL.pdf

 

Here is a great PDF description of various fan clutch types and designs, plus troubleshooting, also from Hayden:

 

 http://www.haydenauto.com/upload/HaydenAuto/Documents/Cat_Hayden/Fan_Clutch_Operations_TS_6980012.pdf

 

Overall, you'll need to work around the DTC codes if you decide to opt for a fully mechanical (thermostatic, viscous) fan clutch.  If you stay with the electronic fan clutch, look into the Hayden unit to see if it has wiring improvements over the Mopar unit.  (It may be identical, so confirm before buying!) 

 

If you're stuck with the OEM type, electronically controlled fan clutch unit, consider fabricating a sleeve mount or harness clamps that will relocate and secure the wiring far enough away from the flexing fan.  If the harness can be moved that much, this could solve the issue of wires getting chafed by the flexing fan.

 

As a last consideration, Derale and others make replacement fans that might be more rigid or offset slightly in their mounting location.  Maybe the correct fan could ensure or provide clearance to the wires if the fan hits water.  Any fan must also have sufficient clearance to the radiator core and shroud.  Here is the Derale catalog download for fans.  You can make some comparisons:

 

http://derale.com/images/pdfs/Derale-Catalog-2014.pdf

 

These are places to start...You have an unusual issue here.  Clearly, Chrysler did not expect these trucks to do much water fording.  Let us know what works here, happy to provide more ideas and suggestions.

 

Moses

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