Thread: The backyardians thermo fan fix

Weather it's a blowout on the tracks or a slowly dying thermo clutch that you JUST cannot afford to fix. Here is your get me home fix .

REQUIRES:

4 decent tension screws appx 70mm long OR nuts/bolts of same length
1 drill bit (size differs between the 2, I used a 6mm bit and bolts)
1 drill (duh!) cordless if your hitting the trails.
1 angle grinder (preferably cordless. I like cordless but needs 2 big batteries)
1 cutting disk for said grinder
Tools needed to screw/bolt together Allen key set to remove fan from clutch
400mm wide shifter or multi grips of similar size, a way to wedge your water pump pulley (my belt kept slipping)

Optional: bottle of k-seal sealant (for people who have head gasket issues or just to ensure any leaks are sealed)


This hot-fix works so very well. But it does mean your constantly pulling power off the engine untill you either electric convert or buy a new clutch but it will surprise you. When it's warm it runs quite well (albeit LOUD after 3k rpm)

Step 1: remove fan from car
Pop your upper fan shroud off. Look down behind fan
It's a left hand thread. So wedge your belt hard onto your pump pulley to stop it spinning, get your shifter or multi grips on the nut like point behind the clutch and spin it hard towards the drivers door side. It will be free enough to just spin it off with the fan.

Remove fan from clutch
4 bolts. Allen key setup. Forgot size so keep a whole set of keys handy (metric I believe)

Grind the rear fins back to housing
Refer to pic. Make sure there's not much fun left to housing

Drill bolt/screw holes
Depending on option. Screws use a bit .5 to 1mm smaller than screws outside thread. Bolts 5.5mm bolt 6mm bit (to account for thread) get it near the centre but not too close you cannot get the bolt in without hitting the centre of the case. Refer to pics once the first hole is drilled refer to next step briefly then return and repeat this step

Cut outside fins back to case
Do this immediately for the first bolt, insert bolt and wind nut up, then at your leisure for the rest, cut exactly like you did on the back side. Leaving them just above the case.

Once all 4 are done tighten them all up tight. Bolt heads on back side nuts on front

Refit fan.


Congratulations. You can now drive on the sun and not worry about it over heating. As you just perma-locked your fan hub. It's noisy but you can be dead certain it's gonna get you home all day every day. Hell! I did this mod after over heating the car 5 times, dropped k-seal in it and towed a 1.2 ton car over 300 Ks in 26 degree weather without temp getting above thermostat opening temp . Unless your radiator ,thermostat or pumps shot you will get home on this. Then to the shop. Then probably never worry about t ever again. Till you get annoyed at how loud the car is. But even then. If you already own the gear this costs probably an hour of your time . Maybe 2-5 dollars for bolts . Tested and proven to 4K rpm (heavy trailer versus steep hill)


This mod was performed on a D1 discovery but should work for most viscous fan hubs

or...

get 2 6 foot lenghts of 6mm rope. place the center of one piece infront of one fan blade and then lay it over the connection point from the pully to the fan hub, turn the fan by hand against its normal direction of rotation.

do the same for a fan blade 180 degrees (or near enough) away from the first blade.

wind the engine over until all the rope is wrapped around the shaft, wrap in electrical tape to stop the loose ends flapping around.

that'll get you home.