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simple replace with 2003 ele fan as outlined on forum fan will work with modified relay fan cost $250 relay cost $55 relay comes with instructions cheapest way to replace fan to work only one problem must have 100 orders for modified relays before shipped or modified 2003 fan ready to install $500 both work fan from existing pluswith signal same as hydro fan
the 2003 ele fan is the way the 2002 has same cooling needs as 2003 my 2002 has had 2003 fan on it for 3 years and 40000 miles no over heating once modified the fan has no return fan is around $250 you will need a 60 amp max fuse two wire connectors put max fuse in main connection on fan cut ground wire 6 in. from connector install the two wire connectors one on ground side one on voltage side paint volt side red hook to to buss connector at fuse box where hot wire bolts to fuse box hookup ground to frame or engine block i used zip tie to strap connector now fuse holder to bracket first you need to modify the signal from the 2002 computer inside the computer to match the fan or modify the fan micro computer in side the fan to match the 2002 they are different signals
use 2003 ele fan modify housing the only controler you need pluswith relay that modifies signal from car computer to fan the 2003 fan is a micro control fan it has slow start to keep sudden draw off alt. pluswith relay 100 amp alt. is strong enough 3 years no problem i build two types of pulswith relays one to mount outside the fuse box and one to wire inside the fuse box or you can modify the the micro controler in the fan after 3 years the chips heat up easer to pluswith relay the system cheapert fix
the pluswith signal green wire white stripe and brown wire voltage goes to a solenoid on back of pump low frequency pluswith =less voltage = open bypass=less pressure=slow fan speed high freguency pluswith =high volt =closed bypass =high fan speed the pump the solenoid the hydro fan all removed all you need is the pluswith signal green wire white stripe and voltage wire brown the signal low voltage low fan high fan must be modified to run ele fan it is not the same signal hence my puswith relay it modifies pluswith signal from green wire white stripe to run ele fan same as factory 2002 hydro or 2003 ele you need no other controlers
Mine is a 2002 with hydraulic fan. They replaced the controller last year. Doing research these types of units, the hydraulic fans, and components tend to start failing at 18-20 years of service, seeing it in 05 jeeps with about 100K miles. While I only have 68K miles, its 18 years old, and we plan to take some major trips starting next year, so plan to preempt issues as the electric fans last forever. More study shows the Flex a lite as easy to install and produces 3300+ cfm at 18 amps, not the mid 40+ amps the ford fans require for a similar cfm. So a lower amp draw lessons the load on the alternator system as well. The Flex-A-Lite 183 will cool a Ram Hemi 5.7 so should do fine in a T-Bird 3.9. So I'm continuing to do research and this fall when the T-Bird comes in for the winter I'll do the conversion.
The electric fan in my 2012 Mustang didn't "last forever". The ball bearings started coming out and had to replace it last Spring of 2019.
