Taurus fan install

[ThatGuy]

I've Googled the Taurus fan install 2 or 3 times this week. My little flex-a-lite wasn't keeping the Ex as cool as I wanted so I went to the J/Y and snagged me one. I've read 100 threads on installing this thing with everything from a hi-dollar controller to just a switch and a constant duty solonoid.
I hooked the fan up with my thermostatic switch and an 80amp constant duty solonoid. Let it sit in the driveway and get to temp to make sure everything was working. Fan kicked on and temp dropped almost instantly. The amp gauge did too. After a few on/off cycles I decided to drive it around. I got about a mile from the house and when I stopped at the stop sign, I noticed smoke coming from the hood. I looked at the temp gauge and it was barely on the "O" in NORMAL. I pulled over and popped the hood to find the fan motor on fire! All the wires were melted and even the wire loom around them was melted in spots. I yanked the HOT wire from the battery and blew the fire out. Drove back home and pulled everything back out.
Went and got another fan and double checked with a friend to see how he had his taurus fan hooked up on his buggy. Come back home and hooked the new fan up with several fuses this time as well as the inline relays that are on the fan from the factory.
My question is this, when I hook the fan up like Mark has his mine runs backwards--his is pulling, mine is pushing---what is causing this?

His is brown/yel stripe wire as ground--blue wire as hot hi side. His is ran through a rocker switch off/on and through the same 80amp constant duty solonoid that I bought.

I hooked mine up just like his and it pushes air not to mention the whole melting thing. What gives?


http://www.rebelrockrunners.org/taurus_install.htm
http://www.jeepforum.com/forum/f13/ford-taurus-two-speed-e-fan-install-pics-233676/
http://www.fordmuscle.com/archives/2003/02/electricfan/

 

[ThatGuy]

Ok so after all the help I got here I got up this morning and tore into this wiring mess again.

I may change some things in the future but for now it works. I started with a 35amp SPDT switch with on-off-on. I ran one side to a 20amp fuse and then to my thermostatic switch and then to the low side on the fan through the factory relays in-line in the Taurus wiring. The other side of the switch is ran to the 80amp constant duty solonoid that is fed off a 40amp fuse and then to the high side of the fan.
When I flip the swith up it runs low and kicks on and off automatically at the desired temp. If I need extra cooling or when on the trail I can flip the switch down and run hi until I turn it off. The center OFF is for water crossings (yeah right) or pretty much shut it off when I"m done riding so I don't get mysterious battery drain.

I've run it around town for the last hour or so to check it out and make sure it functions correctly. So far it's right. No melted wires and the Ex is staying very cool.

If ya got questions I'll try to help any way I can.