Since you have an 04 you have a one piece fan clutch/fan blade. Use the Dorman 620-112 fan blade (22.00 to 25.00 at Auto Zone), and then get a Severe Duty 99-02 Fan Clutch.

Now from what I've read you can use the larger Engine cooling fan from an older 96-98 Toyota Corolla (Corolla has two one for A/C and one for the Engine) and it's supposed to be the same fan motor our D2's take.

Bleed Screw wise when the D2 is completely cooled off remove the bleed screw and using a small funnel top it off with coolant until it's completely full and do it again over the next several days.

 

That's some good information on the early Disco 2 fan clutch. I was going to pick up a Chevy 1/2 ton van clutch, and fan but Autozone didn't have the fan. Now I think Ill go back for the Dorman fan, and early Disco 2 clutch tomorrow.

I read where you can get an AC-Delco 1580341 fan motor as a replacement for the LR OEM motor. I think that's the same motor the Corolla's use.

I'm going to mess with the cooling system once we get the new fan clutch, and fan installed. I'm going to do some more research on that to make sure I fully understand the process.

 

i put in a flex a lite fan to replace the A/C fan. It kicks a lot of air, and cheaper than buying an OEM replacement. You can just switch the fan motor for the A/C fan, but that was not an option for me as I had to destroy the fan to get it out due to corrosion.

I also have switched to an Electric fan out of an 'p5 GTO with a Ron Francis controller, and I love it. The engine really seems to like that. But considering how much time you have invested I can see jus throwing on a viscous fan.

 

I'm still looking into this option for the ac fans. I've been thinking about a dual fan with a controller for a long time, but never really got too involved. Maybe it's time I revisit that. Which setup did you end up going with?

 

On the topic of cooling... how much would a dirt and bug filled ac condenser affect temps? Mine looks pretty ragged, but I don't hear too often of people replacing them. I tried cleaning it once and the fins are just too fragile.

 

All three parts are on order. My local Autozone didn't have the condenser motor in stock so that needed to be ordered, and it'll be in tomorrow. I'll keep everyone posted on this. Here's the part numbers for the items I ordered from Autozone.

Fan Blade: 620-112
Fan Clutch: 922786
Fan Motor: PM9116

 

It was a whole ball of wax due to an electrical issue I had with the A/C system.

After a ton of looking at pics on the internet I found that the GTO fan has 12 and 14 inch fans, and also covers the entire radiator after trimming. Kicks tons of air.

That said, the Taurus fan and the Flex a lite set up with Shroud will work, and I have one of each I would sell you, and a flex a lite controller. You would need to rewire it though. I still have the directions as well. They both worked, but I assumed that the problem with my overheating was related to the fan, found out with a HD Viscous fan installed it was not.

The Ron Francis Controller is FAR superior to the flex lite controller. I installed it on the back of the bracket that holds the ABS ECU, and it was not all that difficult, and having it in the cab was what Ron Francis recommended. It has dual fan control, shut off in case of surges, and stays on for 2 minutes after shutting off. Each of those features can be turned on or off.

I wanted to braze on brackets to my Nissen's radiator, but could not get that to work. So I have them bracketed around the radiator, and it is working fine so far.

The engine loves an electric fan, and I am now running them with a stock alternator, and it's great.

You can find the fans usedcarparts.com or something like that, lots to choose from. The fan motors are available for replacement in the future which is nice, or you could spend more money and get a new shroud and new fans.

Make sure to get the radiator out, trim the shroud. It's important to have the large fan on the passenger side to fit around the thermostat, unless you have gone to the inline thermostat.

 

Never have used a Dorman 620-602. For a 99-02 D2 fan clutch it should be the 620-112 18inch fan blade. Fan clutch that works with that fan blade should be 922790. Both are 100% PNP compatible with a 99-04 D2.

From what I remember the 620-602 requires some cutting to fit. Let us know how it goes.

 

Yeah I figured it was a larger fan diameter. The 620-112 is darn close maybe 1/2 from the top of the OEM fan shroud on both my D2's with perfect OEM shrouds.

I just know when off-roading or driving down bumpy dirt roads the engine/radiator alignment moves slighlty.

 

I actually miss typed the fan clutch number. I did get the 922790 for the 620-602 blade rather than the 922786 clutch.

Just to clarify that the 922790 is the severe duty clutch though, right? The description said it was Heavy duty, but nothing about severe duty.