Taking the rest of the week off work (need to burn my unused vacation time), so I'm digging into it.
Today I pulled the fan (was a PITA, had to resort to a 4lb mini sledge and a concrete chisel to knock it loose) and modded my fan and stock shroud to accept eachother (and riveted them together.
Went to test fit it, and it doesn't clear the water pump:
(Sorry for not clear pic; my phone ran out of juice and my digital camera is junk at night. )
Pics of my assembly I made:
(The wires were cut like that when I bought it. For $2.50, I'm not complaining!)
The issue is the bump on the back of the motor is smacking the threaded snout of the water pump. I clear everything else.
Do they make a water pump for the 4.0 that doesn't have the snout? I'm not too opposed to a water pump replacement considering that I hammered on it a bit to get the fan clutch off.
Or is there something I did wrong? I trimmed the Taurus shroud a bit shallower to clear already (1/8", on bottom end )... I'm not thrilled on trimming more as I don't want to risk vibration/flutter causing the fan to jump forward and kill my radiator.
Edit- Rechecked, no, the entire motor is hitting the water pump pulley. The last picture is misleading; the motor hangs out the back of the housing by about 6-10mm or so.
Going to see how much more I dare trim/shim the motor forward... ugh. Edit- about 9mm of existing clearance. Not much... about the amount I need, which is too close since I want to have some clearance.
Did ford make other 2 speed fans besides the Taurus fan? The one I have is a genuine ford part (or at least has Ford stamps and a part number in the plastic)... Perhaps the issue is the fan itself?