Tophers World
I wanted to not only fix the problem but take it up a notch so this won't happen again. Emmet hooked me up with a heavy duty radiator. It's twice as thick as the stock one so it's a good start. I have seen a few write-ups from people that ditch the clutch fan and go totally electric.
I had to rework it. The next weekend I went back to Pick-a-part and got another 3G from a Taurus and a couple water pump bolts off an older It only squealed once before since I installed it and it was just for a second at startup. One is switched to the AC condenser. It seems to be doing OK so far. We then installed the first 3G alternator. I wanted to not only fix the problem but take it up a notch so this won't happen again.
I like the idea but I want total cooling action. I headed to the local Pick-a-Part and spent a few hours digging up a couple Ford Taurus 3. These draw a lot of power so I also grabbed a high output amp 3G alternator from a 95 Mustang. My brother came by later to help me with this project. Each one has four nut and bolts holding it down firm. I also had to fabricate some custom brackets since the fan on the far side sticks out a little past the radiator. Here is how the brackets look under the shrouds. We then installed the first 3G alternator. I used 4 gauge switch to starter cables since this is a amp alternator.
We placed a Amp Mega Fuse with a bling bling fuse holder from the audio section since no-one had a normal one in stock. I decided since I had everything out I would go ahead and replace the water pump.
I ended up braking off two of the bolts that go all the way through to the block. We spent the rest of the day trying everything easy outs to welding nuts onto the stubs to try and remove them with no success. We decided to try and use the 5 remaining bolts and a heavy amount of silicone to keep it from leaking. We got everything but the fans wired and started it up. After installing the new water pump, it didn't leak there but did leak between the timing chain cover and the block.
I also got nothing from the alternator so I took it to Pepboys where it failed all tests. So we removed the radiator, all the pumps and hoses and spent hours trying to fineness the timing cover off with no luck. Those two snapped bolts were holding it tight. I finally decided to get tough and using a dremel with a cutoff wheel and a grinder with a cutoff wheel I cut out about half the bolt leaving enough of the housing to be able to eventually get a new nut on there to hold it tight.
Looking at what appears to be a core sample you can see why the cover didn't want to budge. Of course once we got the timing cover off what remained of the bolts unscrewed with ease. It looks like it's time to change the timing chain since I have it broken down this far.
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The next weekend I went back to Pick-a-part and got another 3G from a Taurus and a couple water pump bolts off an older My brother came back for another weekend of torture and we started by placing the new timing chain set in. It's not only cleaner but the new chain made it a nice tight fit.
We spent the next few hours muscling the timing cover back on. It was getting dark so we will continue putting the Beater back together in the morning.
Saturday late start but we got the water pump back on then all the pulleys, serpentine belt and hoses connected. Before we put the radiator back in I decided it wasn't Beater enough. It needs a hole in the fender. With the size of the new radiator and fans I couldn't replace the fresh air intake so I flipped the filter box and made a new one. By the time it got dark we had the radiator back in and all the hoses and stuff back in.
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It was degrees outside on Sunday so not a lot got done. We changed the oil and filter added water and started her up. It seems to be doing OK so far. The 3G from the Taurus works and there are no leaks. I have the fans wired to the relay. I will need a second one for high speed. We got everything but the fans wired and started it up. After installing the new water pump, it didn't leak there but did leak between the timing chain cover and the block.
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I also got nothing from the alternator so I took it to Pepboys where it failed all tests. So we removed the radiator, all the pumps and hoses and spent hours trying to fineness the timing cover off with no luck. Those two snapped bolts were holding it tight. I finally decided to get tough and using a dremel with a cutoff wheel and a grinder with a cutoff wheel I cut out about half the bolt leaving enough of the housing to be able to eventually get a new nut on there to hold it tight. Looking at what appears to be a core sample you can see why the cover didn't want to budge.
Of course once we got the timing cover off what remained of the bolts unscrewed with ease. It looks like it's time to change the timing chain since I have it broken down this far. The next weekend I went back to Pick-a-part and got another 3G from a Taurus and a couple water pump bolts off an older My brother came back for another weekend of torture and we started by placing the new timing chain set in.
It's not only cleaner but the new chain made it a nice tight fit. We spent the next few hours muscling the timing cover back on. It was getting dark so we will continue putting the Beater back together in the morning. Saturday late start but we got the water pump back on then all the pulleys, serpentine belt and hoses connected. Before we put the radiator back in I decided it wasn't Beater enough. It needs a hole in the fender.
With the size of the new radiator and fans I couldn't replace the fresh air intake so I flipped the filter box and made a new one. By the time it got dark we had the radiator back in and all the hoses and stuff back in. It was degrees outside on Sunday so not a lot got done. We changed the oil and filter added water and started her up.
It seems to be doing OK so far. The 3G from the Taurus works and there are no leaks. I have the fans wired to the relay. I will need a second one for high speed. I'll do that next week.
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Here's my solution for the cold air intake, for now anyway. I got a second relay and made a bracket to hold them in place. For now I wired the low speeds only. One is switched to the AC condenser. It will run with the AC on. The other is connected to the Fan controller from my old wimpy fan.
It is set to degrees. I also ran the high speed wires from the fans to the relays so I can easily switch it out if necessary. I drove it about five miles and popped the Mega fuse.
I will have to take a look and see what caused that to happen. It worked fine at idol I ordered a Amp circuit breaker from a car audio place to replace it. I installed the circuit breaker and managed to break it within a few minutes of installing it. The web page states that you push in the button to reset it. I did that since it was sticking out and went to move the arm where it says A.
I broke a small piece of plastic on the inside. When I took it apart it could see that pushing it in actually breaks contact.