How to Take Off a Fan Clutch in a 2005 Ford F-150

The 2005 F-150 was just a year removed from a redesign that eliminated the older, rounder body style in favor of a more truck-like design. The 2005 F-150 came standard with a 202-horsepower, 4.2-liter V-6 engine that used an engine-driven fan with a temperature-controlled clutch. The clutch would engage further as engine temperatures rise, increasing the speed of the fan in the process. Replacing the fan clutch on the standard 4.2-liter engine requires removing the fan shroud and fan along with the clutch, but it is a pretty straightforward task.

Instructions

Removal

1

Pry up the centers of all seven push-pin-style retaining clips from the radiator sight shield using a flat-head screwdriver, then pry out the clips from the sight shield. Lift the sight shield off the radiator.

2

Unplug the wiring harness connected to the intake air temperature sensor, which is the only sensor inserted into the air cleaner outlet hose. Pull the crankcase breather hose from the air cleaner outlet hose from its inlet on the air cleaner outlet hose. Loosen the two hose clamps on the air cleaner outlet hose, one securing it to the throttle body and one to the air cleaner, using a flat-head screwdriver, and pull the air cleaner outlet hose from the engine compartment.

3

Hold the fan clutch steady with the fan pulley tool while loosening the fan clutch nut using the fan clutch nut tool until the clutch is free from the water pump.

4

Unfasten the bolts securing the fan shroud in the engine compartment using a ratchet and socket, and pull the shroud, fan and clutch from the engine compartment.

5

Secure the clutch and fan in a soft-jawed bench vise and remove the bolts securing the fan on the clutch using a ratchet and socket. Remove the fan from the old clutch.

Installation

6

Remove the old clutch from the vise and secure the new clutch in the vise. Slide the fan onto the new clutch, aligning its bolt holes with those on the clutch and hand-thread the fan-to-clutch bolts. Tighten the fan-to-clutch bolts to 13 foot-pounds with a torque wrench and socket.

7

Guide the fan shroud, fan and clutch into the engine compartment as one assembly. Hand-thread the fan shrouds retaining bolts, then torque the bolts to 53 inch-pounds with an inch-pound torque wrench and socket.

8

Hand-thread the new fan clutchs nut onto the water pump . Hold the fan steady with the fan pulley tool, then torque it to 41 foot-pounds using a torque wrench and fan clutch nut tool.

9

Press the air cleaner outlet hose onto its inlet on the air cleaner and throttle body, then tighten its two hose clamps with a flat-head screwdriver. Press the crankcase breather hose into its inlet on the air cleaner outlet hose and plug the IAT sensors wiring harness into the IAT sensor.

10

Reinstall the radiator site shield and guide the seven push-pin-style retaining clips into their holes. Press the center of all seven retaining clips downward until each center is flush with the head of its clips.