Radiator fan assembly removal procedure

1995 3.8L Windstar
The CD-ROM says this, but it does not look like its true:

Removal and Installation

1. Remove CCRM as outlined.

2. Disconnect cooling fan motor connectors.

3. Remove fan shroud retainers from radiator (8005).

4. Slide engine cooling fan motors (8K621)/ fan blades (8600)/ fan shroud (8146) assembly clear of radiator tank hose connector and lift up past radiator.

5. To install, reverse removal procedure. Tighten fan retaining bolt to 2.6-3.7 N-m (23-33 lb-in). Tighten shroud retaining nuts and bolts to 8-12 N-m (71-106 lb-in).

-----------------------------------
I do not see why removing the CCRM would help with anything, but what does seem to be in the way is what I think is the hydraulic unit and even if I pulled that out it still looks like I'd have to bend the radiator coolant hose to squeeze it out and it would have to be one hell of a contortion act to get it out too.

Has anyone else done this? Did you have to remove the hydraulic unit, the ccrm or the main large coolant hose?

EDIT: I'm doing this cause I don't like the new fans. They vibrate the van excessively cause they don't fit quite right.

This is what the ford manual says:

Cooling Fan Motor, Fan Blade and Fan Shroud Assembly, Electrical
Removal and Installation

Remove CCRM as outlined.
Disconnect cooling fan motor connectors.
Remove fan shroud retainers from radiator (8005) .
Slide engine cooling fan motors (8K621) / fan blades (8600) / fan shroud (8146) assembly clear of radiator tank hose connector and lift up past radiator .
To install, reverse removal procedure. Tighten fan retaining bolt to 2.6-3.7 Nm (23-33 lb-in). Tighten shroud retaining nuts and bolts to 8-12 Nm (71-106 lb-in).

The CCRM:

Constant Control Relay Module (CCRM)
The constant control relay module (CCRM) activates the cooling fan motor when the coolant reaches a specified temperature or when the engine reaches a specified temperature. On vehicles equipped with air conditioning, the cooling fan motor is activated whenever the A/C clutch (2884) is engaged.

NOTE: Cooling fan motor remains on and will not cycle off with the A/C clutch engaged.

An exception to this is when vehicle speed is over 105 km/h (65 mph) and coolant temperature is below 104°C (220°F). The fan will then automatically shut off.

The cooling fan is controlled during vehicle operation by the powertrain control module relay (PCM relay) (12B577) and powertrain control module (PCM) (12A650) which energize the cooling fan in low speed under the following conditions:

engine temperature is higher than normal. (Fan starts running at 102° C [215°F] and stops running at 99°C [210°F]).
A/C is on and vehicle speed does not provide enough natural airflow. (Fan starts running at speeds at or below 97 km/h [60 mph] and stops running at 105 km/h [65 mph]).


Thats a copy and paste STRAIGHT out of the online ford manuals. Hope it helps.

You are making me wonder now since I've checked and replaced so many other things if a problem I haven't mentioned here (but mentioned many times in other threads) is being caused by a faulty PCM Relay.

Other than that basically you posted what I did. thanks for your time though.

I opted not to replace the fans cause as far as I can tell I would need to remove the hydraulic control unit and the upper radiator coolant hose. I see no other physical way to get the fans out since there is no room to twist or turn them out.

New fans?
Vibrating?
FORD TSB 97-10-4
A Correction to FORD documentation that had stated that the fan motor/blades/shroud can be serviced individualy....no longer what they recommend.

The TSB states that the WHOLE assembly is to be replaced....all 1 unit.
P/N F78Z8C607BA
List price in AlldataDIY is $318.13

The motor, fins, shroud should NOT be serviced separately.....or disassembled.
The reason is that the assembly is "dynamically balanced" at the OEM....to elliminate vibration.
Vibration is not only anoying......it is hard on the fan motor bearings....and can get worse.....and lead to the fan motor failing.

This TSB covers your '95 also.

As far as removing......I remember the Antilock Braking Unit being in the way when I was moving the fan assembly to install my tranny cooler.......and being afraid to touch it.....I tilted the fan assembly in and slid my hand down in to do what I needed.
So I have not had my fan assembly out.....but can verify that it would seem that it may have been overlooked in the instructions.
The instructions that I see for the '96 seem to be the same....no mention of the ABS unit.

Removing the CCRM is a safety issue I think. Choices. Disconnecting a battery cable should do the same. What hydraulic control unit are you referring too? (I'm not familiar with your year model.)

On my '99 removing the fan shroud was never a big deal. But removing the radiator, with the engine in place, was a real challenge. Even with the exhaust manifold removed. I ended up grinding the welds out of the hood latch down assembly ... the one welded to the radiator support. Those old weld locations now have nuts and bolts.

Well, that explains a lot (about not disassembling the fan assembly).... I can easily see an aftermarket seller not taking the time to properly balance the assembly. It does vibrate a lot. This gives me ammo to pursue getting the manufacturer to give me money to put the old fans back in.

I think its mighty convenient they leave out that the coolant hose & hcu has to come off. I guess since the 95 3.8L is a step-child 1st year run a lot was not done right.

12Ounce - It almost seems like they meant to say HCU instead of CCRM because of the fact that it is definitely the HCU in the way...... though if you pulled the coolant hose out on that side...... you MIGHT be able to angle the fans out of there in one piece.

HCU - It is my understanding that the HCU is the antilock brake system mechanical/electrical "hub" if you will..... here is where all the brake lines intersect and where ABS does its good stuff.

Interesting that it should be located there. Of course, where that stuff is on my '99; underneath ... it has heat problems, so maybe near the radiator makes sense.

They kind of lump the '95 in with the 96-98 windstar as that will be pretty much the same in that year grouping......maybe even the newer ones for this particular repair....but I don't personally know about '99 and newer.
Point being.....a lot of things are the same for the '95 as the '96 - '98 as far as repair process......big difference is that they went to a HUGE upper intake manifold with the extra port for each cylinder on the post '95 units....and a few other differences like the fuel pressure regulator being on the opposite side of the motor.

They seem to have overlooked the ABS unit in the instructions for my '96 as well as your '95.

The important thing here is that the fans should NOT.....NOT....NOT be vibrating.

Dorman (fans assembly manufacturer) wrote me back and is trying to sluff it off on RockAuto. I don't see how they can do that when RockAuto didn't make the fan assembly.

Unless they are trying to say that the assembly that you got should not be listed for use on the windstar.
That would not make much sense....as it would vibrate on whatever vehicle it is installed on......and it would be not good to have it vibrate on any vehicle.

Strange.... my trusted shop only charged me for 40 minutes to do this way back when. I wonder if they found a way to follow the instructions rather than what I've said here... I just don't see how .... unless somehow they pulled the fans from UNDER the vehicle while on a lift.... but I haven't looked from bottom to see so I dunno.