From time to time I get questions about the FFD aluminum radiator and triple fan kit. So I thought I would answer some of them here. At the time of posting this, I have had the new setup installed for 6 months.
The aluminum radiator was very impressive out of the box. I have no data to make specific claims, but the all-aluminum 2 core radiator seems like it would be superior over the stock radiator in its ability to cool. With that being said, I’ve been told that the OE mechanical and electric fan can flow an estimated 5200 CFM (4000 CFM for the mechanical and 1200 CFM for the electric) whereas the FFD triple fan kit can only flow 3300 CFM (1100 CFM for each fan). Based on this information, one would conclude that the stock setup flows more air.
Normally, I would never abandon the mechanical fan. As a matter of fact, I upgraded to the Mopar Heavy Duty Cooling fan kit on my 2007 KJ because it only came with the electric fan. But since my XJ is primarily used for local utilitarian purposes (towing a firewood trailer, hauling brush, commuting to work and back, etc) I decided that the advantages switching to an all-electric system would outweigh the disadvantageous. There is a small gain in horsepower by reducing parasitic loss from the crankshaft, which also reduces engine stress and increases fuel efficiency. For those who are looking for noise reduction, the FFD fans are significantly quieter than the stock setup. And lastly, this kit has an optional manual switch so you can turn the fan’s on and off at your leisure. You can also set the thermostat to kick the fans on automatically.
To date, I have not had any overheating problems. One advantage to living at 7,000 feet is that we rarely see summer temperatures above 92*F, however, I believe that the low humidity and thin high altitude air works against me since there isn’t much dense air for the fans to push. I’ve towed 2,000 lbs with the AC on at speeds as low as 20-30 mpg without any major heating issues. If you are into hardcore off-roading, towing, or working your Jeep in high ambient temperatures, this kit might not be the best option. Again, lower altitude and higher humidity might make a measureable difference, I really don't know. I saw temperatures rise when I was towing 2,000 lbs at low speeds in mountainous terrain with the AC on, but they dropped as soon as the terrain leveled out. I will say that my temperatures never got high enough to cause me to be concerned.
Since installing the radiator, I’ve had several leaks. Thankfully, all the leaks “so far” have been fittings and/or plugs. My first leak was from the aluminum threaded cap on the front side of the radiator. I was told that this threaded fitting was designed for the European models. FFD told me to silicon the threaded cap and that would solve the problem. So, that’s what we did and we haven’t had any problems since. I just wished that piece of information would have been in the install directions.
The next leak came from the plastic drain plug. After calling FFD, they told me to upgrade to the nicer threaded brass drain plug. They sent me the new "upgraded drain plug" for free. We installed the new brass drain plug and haven’t had a leak since. So if you order this kit, I would suggest asking for the upgraded drain plug.
My current leak started a few weeks ago when temperatures were dipping down to 5* degrees at night. I’m not sure, but it seems that the aluminum is contracting and expanding with our extreme temperatures resulting in early morning leaks. Once the radiator is warm, the leak stops for the remainder of the day. I’m hoping that my current leak is coming from the fitting rather than the welded seem. I will update this thread on the final results.
Two months after the install, the fans were working loose from the radiator. I called FFD and they said that I needed to put a dab of superglue on the tie straps to keep them from separating. Again, this step was not in the directions. FFD sent me new tie straps and super glue free of charge. Once we installed the new tie straps and dabbed them with super glue, the fans appear to be holding up just fine. I drive on very aggressive washboard roads a lot.
Overall, I want to be clear, FFD’s customer service has been great. They were quick to answer my questions, quick to find a solution to my problems, and quick to send out replacement parts free of charge.
Anyway, this will answer some of your questions. Let me know if you need pictures, more information, etc. I’d be happy to help in any way that I can.
