What's new
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

windstar fan wiring - Don't beat me up!

brans87

brans87

1/2 ton status
- In Memoriam -
Joined
Sep 16, 2013
Posts
3,018
Reaction score
838
Location
North Carolina
So looking for a good diagram on how to wire my windstar fans up correctly and without a headache like I have given myself already.

I want fans to work with temp and with a/c. Pretty simple but for some reason I keep beating myself up on this and making it harder then need be.

So with all this said anyone have a diagram? Truck is 87 K5 with Serp setup.
 
I don't have a diagram for you but your overall game plan should be fairly straight forward. I would add a couple of relays depending on how you want them to operate. I'm using the dual speed Taurus fans with Volvo relay pack running them switched via LS computer. I have a toggle to override if needed.

You'll need:
12v fused source to relay
12v from relay to fans for power
Good ground to relay
Ground for fan
Trigger (a/c switch or toggle or thermostat)

A quick google search found this for you. Should help.

http://www.nloc.net/vbforum/showthread.php/215817-Ford-Windstar-Dual-E-Fans-75-00
 
I got most of that but thinking on how to do trigger thinking a/c switch for one fan and other fan use coolant sensor.

Looking for a ground bus bar and power bar also as I am sure will add other things down road and this would help with the clutter.
 
Sorry, I can't read the 400 posts in that other thread to see if it was covered, but I would think using the compressor to trigger the fan(s) with AC would be the right move.

I'm not real schooled on AC, but my understanding is that the more air you can move across the condenser the colder your AC, so I would think both fans on max would be the right choice there. And simplify wiring.

The other thread probably covers what switch(es) to use for temp, I know GM used a fan switch in the Buick GN's that seemed like a good option. GM also used a high temp (240*?) "emergency" coolant switch on the TPI cars of the late 80's early 90's, and something like that probably wouldn't hurt as a failsafe. Not a fan of temp switches that are "on" under the thermostat rated temp, since the fans will be unlikely to ever turn off.

Also not a fan of toggle switches for fans, unless using them to turn the fans off for water crossings. Just personal opinion, but bad things happen when fans aren't turned on and a vehicle is running.
 
dyeager535 said:
Sorry, I can't read the 400 posts in that other thread to see if it was covered, but I would think using the compressor to trigger the fan(s) with AC would be the right move.

I'm not real schooled on AC, but my understanding is that the more air you can move across the condenser the colder your AC, so I would think both fans on max would be the right choice there. And simplify wiring.

The other thread probably covers what switch(es) to use for temp, I know GM used a fan switch in the Buick GN's that seemed like a good option. GM also used a high temp (240*?) "emergency" coolant switch on the TPI cars of the late 80's early 90's, and something like that probably wouldn't hurt as a failsafe. Not a fan of temp switches that are "on" under the thermostat rated temp, since the fans will be unlikely to ever turn off.

Also not a fan of toggle switches for fans, unless using them to turn the fans off for water crossings. Just personal opinion, but bad things happen when fans aren't turned on and a vehicle is running.
Click to expand...

I think your on the same page as me, more switches can get you in trouble. Rather have it ran with ignition so when you cut truck off it kills the power.
 
That wiring diagram is well done, if you have no reason for stream crossings you could eliminate that portion, but that's not a negative. Now that I think about it, unless you were stream crossing all the time, you could just unplug the dang fans when necessary lol.

Derale and others make fan controllers that integrate all the stuff into one clean unit, but the negative reviews I read seemed to have enough validity and consistency to indicate that for $150+, doing it yourself is the better method.

If you are fuel injected (and have AC I believe), I'd use the same relays for the fans as the fuel pump/AC, so that worst case, if ever needed, a failed relay could be replaced without needing spares.

IME under normal and moderate load on the truck (climbing steep logging roads at low MPH in 70-80* weather towing a small trailer) a single fan is enough to keep it cool anyway, so a single relay failure wouldn't be an issue if both fans were set to be on at the same time. I just consider it unnecessary load.

The other problem is that both fans coming on at the same time MAY be enough to make the engine stumble. My LS1 fans were able to stall the engine when they came on at engine startup. Don't think the engine was running quite right, but they put a large strain on the electrical system.
 
Last edited:
I think me and a buddy got it figured out Going to take a few things to work and play around in any spare time.

Yes TBI and like that idea there!

Note taken on last part can only try and see I guess just make sure battery and alt are up to par also.
 
How do you make 1 load come on with 2 sources? It's called a diode. You'll see them plugged in like fuses in some electrical centers. Then you only need 1 relay per fan.

For the load of the A/C compressor and 2 fans all kicking on at once, I have a little solenoid plumbed to the throttle body to let some air bypass the throttle blades.
 
Did you run it without the solenoid first? Were you starting both fans at once?

I would *think* the IAC would force the engine to keep a stable idle, but I can see an issue if the fans both kick on at the same time.

It's not the voltage that's an issue, it's physical load on the engine from the alternator. *Perhaps* staggering startup, if possible, would help? One of the reasons I'd consider something like a primary/secondary fan setup, with the second fan triggered by AC request and/or slightly higher engine temp than the primary fan temp sender.

The later electric fans are running dual speed modules (I've seen it in the Ford products), and I'm guessing PWM to vary fan speed based on demand, instead of being on/off, which would lessen the impact as the fans come on.
 
I considered staging the fans (and probably should - like 2 different temperaturs), but they've triggered together for several years never had problems with it stalling the engine or anything. I wanted both with the A/C because more airflow is better, right? I only give the engine extra air for the compressor. I could set the ECU to increase idle speed with compressor on, but would have to run another input to the ECU to tell it when A/C is on. Otherwise all you can do is ask it to hold the same idle, but standard practice is to have a little more idle speed. I guess I would change the setup if it didn't work so well.
 
On the electric fan setups (cars) they bumped idle both for fan and AC request, I'm surprised they didn't for the trucks, but much of that must have to do with the mechanical fan.

Pretty hard to control electric fans precisely without either a dedicated fan controller, or an ECM that takes all that into account.

I hadn't considered any of this when I swapped to TPI, but fan control alone is definitely a nice side benefit. Of course, I didn't NEED electric fans, but I digress. Fun to play with lol.
 
Blue85 said:
How do you make 1 load come on with 2 sources? It's called a diode. You'll see them plugged in like fuses in some electrical centers. Then you only need 1 relay per fan.

For the load of the A/C compressor and 2 fans all kicking on at once, I have a little solenoid plumbed to the throttle body to let some air bypass the throttle blades.
Click to expand...

Blue I would be interested in seeing pictures of your setup and a drawn diagram of your set up. It has my intrigued as does alot of your post and ideas.
 
Relays are just 2 hot and 2 ground. The one +12 just turns on the other +12 that goes to your fan and the temp sensor is hooked to ground. The temp sensor can be bought from Speedway Motors for $25. Don't know about your AC. The hot and grounds are opposite each other. If you have a 5 prong relay the center one is opposite of the power so one is on when the other is off. (Optional)

http://www.gtsparkplugs.com/images/mini-automotive-relay-wiring-840x.jpg
 
I have this setup on my 83 and it works fine.
 
is the ford windstar still the best solution out there? also I see Wikipedia says 1994-2003.... is there a "Preferred" year over another?
 
RootBreaker said:
is the ford windstar still the best solution out there? also I see Wikipedia says 1994-2003.... is there a "Preferred" year over another?
Click to expand...

So far haven't seen anyone say there is better. The Windstars main advantage seems to be how it fits. I don't recall any other fans being mentioned that are as easy to fit in the trucks.

Problem with many of the other factory electric fans out there is that they use really weird (to me) mounting systems...they aren't bolted in, they rely on brackets to hold them in place, and since everything is plastic, it's molded in odd shapes that are hard to work with, and often the way they are designed makes it hard to use simple mounting methods. The Windstars I believe are setup such that literally they can be bolted up to the truck.
 
dyeager535 said:
So far haven't seen anyone say there is better. The Windstars main advantage seems to be how it fits. I don't recall any other fans being mentioned that are as easy to fit in the trucks.

Problem with many of the other factory electric fans out there is that they use really weird (to me) mounting systems...they aren't bolted in, they rely on brackets to hold them in place, and since everything is plastic, it's molded in odd shapes that are hard to work with, and often the way they are designed makes it hard to use simple mounting methods. The Windstars I believe are setup such that literally they can be bolted up to the truck.
Click to expand...


thanks very much....

scored a fan setup LOCALLY!!!! $40!!!! plus I told him I wanted the wireharness... they said they have to cut it off at the firewall plug. Was hoping the relays were going to be under the hood and attached... oh well...
but ONLY $15 for whatever part of harness they give!!!! WOOOT!!! and they said they will cut and give me as MUCH as they can!!! HAH..
so now I can get my defective clutch fan setup out (which I do not overheat on but a guy I know stuck his hand down and stopped my fan from turning while truck was running - I know dumb move but that was he not I)
 
I've gotta ask, cause I've gone in circles looking for the answer. My Googlefu is down.

I'm looking for which colors to use on the big fan. The small one is simple, 2 wires, one is black.
Big fan has 3 wires. Blue, brown, and black. I just want to wire them up in high. These are replacing my Griffin radiator fans, which means I'm already set up for relays and such. Not looking to change electrical, just looking to find the right colors for the high circuit.

I haven't hooked them to power yet but I've come across things in the past where I need to power TWO wires at the same time to achieve something versus different wires. Just wondering if this is that scenario before I go touching wires to a battery. :D
 
You must log in or register to reply here.

Latest Posts

Top Bottom