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Old 06-24-2013, 12:26 PM   #1
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HELP: Electric Fan and Overheating

Hey guys, just joined the forum and im in need of some serious help. This is long but I want to give all the info I have collected thus far.

2 weeks ago I noticed my Electric Fan (Flex a lite) wasnt sounding as strong as normal. Usually it sounded like a plane taking off and would cycle on and off 3-5 times after being parted and shut off. I thought nothing about it at the time when it sounded weaker. Last weekend I went to the store and waited in the jeep for my girlfriend to come back out. Noticed my temp gauge was above 210 where i always run. Fan never kicked on. Next thing I know I over heated and blew a radiator (cracked at the top). Replaced radiator and put fan back on (worked/sounded normal) and the thermostat was closed but could feel it open at the desired temp. A few days later fan started acting up again. Yesterday I was playing with it and turned the A/C on which is wired to the fan so it should come one when compressor does and nothing happened. I was beginning to overheat again and noticed the thermostat never opened and thought "ok maybe fluid has to come thru for the fan to get the temp of fluid and come on". Replaced thermostat and it is still not coming open and fan still will not come on. So now I dont know if the fan needs to kick on and then thermostat will open. HELP

Thanks for any insight and suggestions!

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Old 06-24-2013, 12:35 PM   #2
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Well im not familiar with the flex a lite fan.

But i did my research and found that the temp sensor that tells the fan the temp is a wire in the radiator itself so in order to make it work hot water has to come to the radiator if not it will never kick in.
So i would suggest to change the thermostat, and check the temp sensor for the fan. And check how it goes. Hope this helps.

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Old 06-24-2013, 12:42 PM   #3
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Well im not familiar with the flex a lite fan.

But i did my research and found that the temp sensor that tells the fan the temp is a wire in the radiator itself so in order to make it work hot water has to come to the radiator if not it will never kick in.
So i would suggest to change the thermostat, and check the temp sensor for the fan. And check how it goes. Hope this helps.

This was my thoughts also. I replaced the thermostat yesterday and isnt opening still. I dont know if it was a bad thermostat or what, but i bought one of the Fail Safe brands for this reason so it could possibly help diagnose problems with it sticking etc. its suppose to lock open if it ever finds itself stuck closed passed the 195 degree it needs to come open at, if that makes sense
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Old 06-24-2013, 12:49 PM   #4
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Replace the thermostat, don't use a failsafe one. All though it's probably not the issue here, the fail safe thermostats don't like the TJ, they tend to run hotter than most vehicles which causes the thermostat to almost always fail in the open state after a couple weeks of use.

Check to make sure your fan controller hasn't melted.
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Old 06-24-2013, 01:03 PM   #5
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Replace the thermostat, don't use a failsafe one. All though it's probably not the issue here, the fail safe thermostats don't like the TJ, they tend to run hotter than most vehicles which causes the thermostat to almost always fail in the open state after a couple weeks of use.

Check to make sure your fan controller hasn't melted.
Would have never known that failsafes arent to safe for TJ's without these forums, Thanks alot! The controller hasnt melted, I was able to spin the fan by hand and it started up but was extremely low and you couldnt even hear it. What could possiblly be keeping the thermostat to keep staying shut right now even with that fail safe on there? yesterday it got to 230ish idling within 7 minutes or so and the thermostat never opened still.
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Old 06-24-2013, 01:08 PM   #6
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Did you check all the wires going from the power o the fan? Maybe a little cable is broken and not passing all the voltage needed.
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Old 06-24-2013, 01:57 PM   #7
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Did you check all the wires going from the power o the fan? Maybe a little cable is broken and not passing all the voltage needed.
I thought that I did but maybe I need to go back and look at them again. the positive wire at the bottom sparks when I remove it from the fan and put it back on so i thought surely there is no nicks in the wires. Not any visible anyway.
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Old 06-24-2013, 02:34 PM   #8
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Ive been reading on a few places online about "burping" the system after fluid loss. Could this be the reason why the thermostat isnt opening? Due to air in the system?
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Old 06-24-2013, 03:24 PM   #9
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Ive been reading on a few places online about "burping" the system after fluid loss. Could this be the reason why the thermostat isnt opening? Due to air in the system?
Maybe. Maybe not to be honest i never burp my cooling systems well all my cars are from the 70's and they never show a sign of problems but im not sure with newer cars.
Its worth giving it a try.
One less thing to worry about.
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Old 06-24-2013, 05:41 PM   #10
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I found that I needed to burp the system when I recently replaced the water pump. It's certainly worth a try.

I would also check your relay that leads to the fan. If the relay is going bad, it could explain why it was intermittently quieter or not working at all. The relay could be sticking someplace between the "off" and "on" positions.
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Old 06-25-2013, 10:55 AM   #11
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I found that I needed to burp the system when I recently replaced the water pump. It's certainly worth a try.

I would also check your relay that leads to the fan. If the relay is going bad, it could explain why it was intermittently quieter or not working at all. The relay could be sticking someplace between the "off" and "on" positions.
Where is the relay? I have 3 wires going to the battery. Two with inline fuses and they are good.
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Old 06-26-2013, 09:22 AM   #12
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There has to be a controller someplace that turns the fan on and off. The controller likely turns a relay on and off, since the fan is probably a relatively high current draw. I'm not sure how your system is hooked up or where it would be, but I imagine there is one someplace....
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Old 06-26-2013, 10:41 AM   #13
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There has to be a controller someplace that turns the fan on and off. The controller likely turns a relay on and off, since the fan is probably a relatively high current draw. I'm not sure how your system is hooked up or where it would be, but I imagine there is one someplace....
I assume he has a Flex A Lite controller. Most intergrated controller units do not have seperate external relays.

And that's a good question to the OP, what exactly do you have for a controller?

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