E-fans and CAI 5.4 2v

[whtbronco]

Hmm, so call it 2mpg increase with the CAI. That's not bad. It might just be worth the cost, if it's not too loud inside. While I like the sound of a nice powerful V8, the Expedition is not all that though and I like to listen to my stereo

 

[kep5niner]

Received the FF Dynamics e-fans, just haven’t had time for the install. The fan controller that came with the kit did not impress me - a couple of relays, excessive wiring, and the instructions state to mount it in the engine compartment in a “cool, dry place.” Right.

So I invested a couple extra bucks and received the Flex-a-Lite variable speed duel fan controller, PN 31165. I’ve used this controller on several applications over the years with no issues. It will make for a neater install, with the other improved features associated with this controller.

I’ll let you people know how it goes.

 

[whtbronco]

Sounds like the Flex-A-Lite controller was a good idea. That is funny, a cool, dry place in the engine bay.

 

[lgauth7]

View attachment 79984
View attachment 79985

Worth it.

Where did you score the radiator shroud decal? noticed it was missing on the before and there on the after picture I'm looking and cannot find them.

Also very interested in your review of the FF dynamics kit as i was looking at those but was unsure of construction. Was thinking of going with an underdrive pulley kit at the same tome for better mileage.

 

[kep5niner]

Good eye. For the decals, I carefully removed them from the old radiator cover with a heat gun and patience. Replacement decals seem unobtainable.

I completed the job, and will follow up with a comprehensive write-up.

 

[kep5niner]

I finished up the FF Dynamics e-fan installation. Recall FF Dynamics is the only ones that made a “custom” e-fan for the downflow radiator in my EB. First off, their fan controller was questionable at best, so I went with the Flex-a-Lite variable speed controller. FF Dynamics kit came as two stand-alone fans. I didn’t like that, so I bolted them together.




Then I had to fab a bracket to hold the fan controller. I used 2” angle 3/16” aluminum, and oriented in basically the same location that the complete Flex-a-Lite kit puts it.

 

[kep5niner]

Controller installed:



Fans installed on the radiator:


If that looks like a new radiator, that’s because it is. Turns out that the side brackets that bolt to the radiator had to be cut to make room for the fans. You can see on the left bracket in that pic, as I was test fitting. And don’t try to cut those brackets with the radiator installed. Hence the new radiator…

 

[kep5niner]

 

[kep5niner]

Finished product. Fired it up, ran through the initialization with the controller, and it’s a first time go. Haven’t logged many miles yet to look at MPG increase, but definitely more pep from the skinny pedal. And much better maintenance access, as well as an overall cleaner engine bay.

 

[lgauth7]

man, the shroud fitment to the OEM radiator would leave me upset. can the fans be clocked within the shroud to not have to trim so much?

Seems like they test fit everything with a radiator without the side brackets installed?

 

[kep5niner]

Your assessment is likely accurate; hence, the “custom” fans. The aluminum shrouds provided with the fans were spot on, but that’s where the custom stopped. The OD of the fans would have made cutting necessary, regardless of clocking them. But great thought!

 

[Hamfisted]

Excellent install work ! Hope you see some gains from the project. Looks like a pilot did it !

 

[kep5niner]

Hey I did spend my first 8 years in the Army enlisted as Blackhawk mechanic / crew chief, and been turning wrenches since before you were with the bigs I still need to take all that time and sit down with the FSDO to get my A&P! It’ll cut down my costs owning the 310

 

[whtbronco]

Really nice job. It sure does open up the front of the engine nicely. The stock fan and shroud are often in the way.

 

[BigRed2004]

The amount of workable space you gained cannot be understated. Oil filter change should be super easy now. I feel like the stock shroud always gets in the way. I think it’s a shame though that FF didn’t make the kit more bolt on ready. And to make each fan separate? It’s good that you got it to fit and have already noticed some driving improvements. But it makes me wonder if the work required makes the choice worth it, if you don’t have the time and budget to do more work beyond install and connect. Looking forward to more info on the gains you get though with no parasitic drag on the engine. You already saw really good gains with the intake and exhaust.

 

[kep5niner]

Quick update on MPG increase after the intake and e-fan install. Bad news: I haven’t seen a discernible increase in MPG so far, because - Good news: I can’t keep my foot out of it.

The throttle response is significantly better, the 5.4 spools up quicker, and couple that with the throaty exhaust, it’s just a blast to drive. Again, I know it’s not a sports car, but most definitely a sure-footed platform that instills confidence on the road and a really great performing truck now.

A little modification required to make the e-fans work, but absolutely worth the upgrade if anyone’s contemplating it.

 

[whtbronco]

Quick update on MPG increase after the intake and e-fan install. Bad news: I haven’t seen a discernible increase in MPG so far, because - Good news: I can’t keep my foot out of it.

I am sitting here just laughing and thinking hell yeah. The smiles per gallon is so much more satisfying. My wife said the same exact thing after we put exhaust and suspension parts on her Monte Carlo.

I keep thinking about the e-fans due to the space it frees up. Despite the fact that I don't think it would be as reliable long term.

 

[kep5niner]

The first e-fan installation was in 2000 with a Flex-a-Lite kit. At that time the fan controller was integral to the fan assembly. In ‘05 that fan controller failed. The only way to replace the controller was to replace the entire fan assembly. I ended up selling that truck and the next guy dealt with it (of course I disclosed the fault).

My next install was in 2011. With that kit, the fan controller was a separate assembly from the fans and shroud. In speaking with Flex-a-Lite, they designed that deliberately so in the event the controller failed, it can simply be replaced without having to replace the entire fan assembly. That fan controller and electric fan kit are still going strong 13 years later in my old supercharged 5.4 3v.

I’ve got faith in the Flex-a-Lite fan controller and confidence in the fans themselves based upon the FF dynamics reviews over the past two decades. I think you could be confident and installing the same! Go for it - it’s only money

 

[whtbronco]

That does make a good case for reliability. It is something to seriously consider once I have my vibrations resolved, rusted rocker and 2 smaller rust issues resolved.