How to: DI viscous fan clutch removal
 

Thought I'd do a little write-up since mine gave me some trouble....

Tools needed:

-Large adjustable crescent wrench or 32mm open end wrench. There is also a specialized wrench available online.
-Vice grips
-Large pry bar


Clamp the vice grips to the pulley, slip wrench onto fan clutch bolt, and use pry bar to keep pulley from turning while you're applying torque to the fan clutch bolt.
http://img199.imageshack.us/img199/6513/97658719.jpg



Insert pry bar between vice grips and pulley.
http://img44.imageshack.us/img44/4610/84622161.jpg



I would recommend putting a rag over the end of the pry bar as to not indent or scratch the pulley, or even put a hole in your serpentine belt. Apply torque to fan clutch bolt counter-clockwise.(if facing the front of the vehicle, you'll be turning your wrench to the left or passenger side)
http://img44.imageshack.us/img44/4130/88242611.jpg


Remove old clutch from fan.
http://img8.imageshack.us/img8/7431/50738833.jpg



Replace fan clutch with new hardware.
http://img35.imageshack.us/img35/7573/21703027.jpg


Simply reverse the process to tighten new fan clutch down. Hopefully your viscous fan clutch bolt isn't as much of a bear as mine was! ;)

-Adam

Thank you for this write up, very simple to do and great pictures.

Looks like you and I have the same drop light.

thanks
 

Played with this problem today.....good write up. Shall give it a try tomorrow.

Is this the same process for a d2? I thought they were reverse threaded...

I just did my water pump. Did not think to do a write up. My fan was a huge pita as well. I used a large set of channel locks, large adjustable wrench and persistance. :D

If you have air tools, a air hammer is a great way to bust that nut loose. You will tear up the nut - but that is ok :)

same for the DII? i have a 2003 SE
 

is this the same process for the DII? i saw someone already asked about it, however, i didn't see a response to it. i didn't want to try it myself until i was sure it was the same process since i've heard removing it is a huge PITA. please let me know!

also, has anyone kept a fan on their discovery with a small nick out of one of the blades? my nick is so small that i'm not sure it is hurting the balance or not and if it's not killing my water pump, i'd rather not replace the 260 dollar all-in-one fan/clutch. oh, also, the nick in the fan blade has apparently been around since i bought the truck 10,000 miles ago.

The D2 takes a 36mm wrench. See if you can lock the pulley somehow and break the nut free. You get a fan clutch tool at Advanced, one piece is the 36mm open wrench and the other piece hooks over the pulley shaft and catches a bolt head on the pulley - hold the pulley still and undo the fan nut counter clockwise when facing the engine. The smaller piece takes a 1/2" ratchet or breaker bar. It's easy to get off with the right tools.
http://shop.advanceautoparts.com/web..._T|GRP2083____

+1 on having the right tools!

Some auto parts stores also have loaner/rental tools. If you go that route and use loaners, make sure you measure the 36mm wrench to make sure that it is still 36mm. I think some Fords may also use the 36mm, so the loaner tools get a lot of use. I've had several sets where the 36mm was stretched or worn out to 38-40mm...being off by this much will make it really tough to get the fan clutch loose.

IMHO after having trouble with the loaner tools, if you think you're keeping your DII for the foreseeable future then spending the $25 on a 36mm fan clutch wrench probably isn't a bad investment.