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Thread: Every single fan blade broke

  1. #1
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    Every single fan blade broke

    I just replaced the radiator in my 2003 bmw 540i due to a leak, i replaced the fan clutch while it was out keeping the old blades and mounting it to the new clutch. after test driving it for about 10 mins i heard a huge sound and every single blade broke off at once. Could this be due to a bad fan clutch or a weak fan? I also tripple checked that the fan was mounted the correct way on the clutch, and the shoud was secure leaving nothing to physically hit the fan blades.

  2. #2
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
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    Ooof. Bummer. Did you escape with no damage in the engine bay or hood? Sometimes blades actually mess the hood and rad hoses and other stuff up real good when that happens.

    Two possibilities, one is that the old fan blade plastic was just super fatigued and ready to let go, but the old clutch was never spinning up, so when it finally got wound up properly it let go.

    More likely is the new fan overspun. What brand of clutch did you use? IIRC a few guys have reported bad new visco fan clutches right out of the box lately, if using the cheapo brands.
    Mostly the reports have been the fan was just too noisy not full assplosion, but that's still a function of spinning up too hard/fast, and maybe assplosion is just a matter of time and/or how aged the old plastic was.

    I'm wondering if one of these aftermarket companies fudged the specs on the clutch and sending out a part thats set to a much lower temp for some different engine and/or that has a shaft that spins at a lower speed.
    Looks like the factory one is 92C. From what I can tell the I6 clutches tend to open a few degrees below that.
    I can't find a reference but a diesel fan should open up a lot lower even, and, could well be setup for lower crank speeds (therefore locking up harder/faster to get equivalent airflow).
    If some supplier made a part cross-ref mistake with a diesel clutch that might do it...
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  3. #3
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    Cheap aftermarket clutch I'll bet. Out of spec? Ha! I've seen lots of them new out of the box that are essentially seized and spin the living daylights out of the fan.
    Old brittle plastic doesn't tolerate that sort of work out.
    Get an OE clutch and blade.
    Quite remarkable that you didn't mention any other damage, consider yourself lucky in that regard.

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    Maybe the bolts were too tight and cracked the old plastic fan where it attaches to the clutch.
    Just leave it off. When I dropped mine last summer and broke a fan blade, I decided to not put it back on. The electric fan does just fine and is much quieter then the mechanical fan.
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  5. #5
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    Just delete the fan clutch. You dont need it

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  6. #6
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    Possible causes:
    - Bad Fan Clutch locking itself. Use Sachs ONLY.
    - Old fan blades (old plastic).
    - Bad engine mounts.

  7. #7
    JimLev's Avatar
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    Quote Originally Posted by BimmerBreaker View Post
    Just delete the fan clutch. You dont need it
    You won't need it until your Aux fan craps out.

    Santa, the bolts from the fan to the clutch are thru metal not plastic on an OE fan. Not sure what the OP used for an aftermarket one.

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    Quote Originally Posted by JimLev View Post
    You won't need it until your Aux fan craps out.

    Santa, the bolts from the fan to the clutch are thru metal not plastic on an OE fan. Not sure what the OP used for an aftermarket one.
    Aux fans have low failure rates, and later BMWs (as early as the E46) went to a single electric fan setup. Running no fan clutch on any of my BMWs, no issue. If the aux fan is functioning and rest of cooling system is healthy I would have 0 qualms about deleting the fan clutch

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  9. #9
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    For the few buck why would one reuse a 15 year old blade?

  10. #10
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    JimLev is offline Artifically Aspirated Moderator
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    Quote Originally Posted by BimmerBreaker View Post
    Aux fans have low failure rates, and later BMWs (as early as the E46) went to a single electric fan setup. Running no fan clutch on any of my BMWs, no issue. If the aux fan is functioning and rest of cooling system is healthy I would have 0 qualms about deleting the fan clutch

    Maybe so, but the ones on the non tu have a higher failure rate.
    Can't compare the E46 aux fan to the 540 fan, they are different. V8's needs more cooling than an i6.

  11. #11
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    Quote Originally Posted by JimLev View Post
    Santa, the bolts from the fan to the clutch are thru metal not plastic on an OE fan. Not sure what the OP used for an aftermarket one.
    That makes sense. It has been several years since I replaced my fan clutch and I couldn't remember.
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  12. #12
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    SpiritMolecule, could you have mounted the blades to the wrong side of the clutch?

  13. #13
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
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    He says he triple chugged that...otherwise woulda been mentioned early. Of course Mr one post hasn't been back ... May never...

    Going strong here on many years of daily driving on Aux-only stupidcharged V8 here, 4-seasons. If anybody is on borrowed time hell it's me, I think it's even the OE factory Aux fan, but we are still rocking!

    In the 10's overnight lately Jim so , don't need too much fan around here ATM. I'm sure you're missing this kind of weather...
    2003 M3CicM6 TiAg
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  14. #14
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    I have been experimenting with fan modifications lately, have modded 2 e46's to the single fan mod with great results. Details here (not my writeup):
    http://www.zhpmafia.com/forums/showt...)-doityourself

    On the e39/e31 front, I have swapped out 2 fans recently, one on m62Tu and the other on an M70 with the following fan from later model 7 series and X5 with mechanical fans:

    Fan Blade 17417504732
    Fan Clutch 17417505109

    BMW fan upgrade.png

    The new fan is quieter, potentially less prone to breakage, and moves more air. The fan blade and clutch must be used together. This is early in testing, but so far, working well. I am not suggesting that we all go out and change our fan blade, just proposing a potential upgrade when doing maintenance.

    Hope this helps.
    Last edited by bdiefAZ; 01-12-2019 at 10:11 PM.
    Regards,

    Brian
    Cave Creek, AZ

  15. #15
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    Quote Originally Posted by geargrinder View Post
    He says he triple chugged that...otherwise woulda been mentioned early. Of course Mr one post hasn't been back ......

    In the 10's overnight lately Jim so , don't need too much fan around here ATM. I'm sure you're missing this kind of weather...
    Love those one posters, drop a question and vanish.

    10°, not missing that weather at all, it's 40° here right now. If it makes you feel better last week I had to shovel a little snow. First time I had to use a snow shovel in 3 winters.
    I was outside today powder coating parts for the '33.
    Last edited by JimLev; 01-12-2019 at 10:56 PM.

  16. #16
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    Quote Originally Posted by bdiefAZ View Post
    On the e39/e31 front, I have swapped out 2 fans recently, one on m62Tu and the other on an M70 with the following fan from later model 7 series and X5 with mechanical fans:

    Fan Blade 17417504732
    Fan Clutch 17417505109

    BMW fan upgrade.png

    The new fan is quieter, potentially less prone to breakage, and moves more air. The fan blade and clutch must be used together. This is early in testing, but so far, working well. I am not suggesting that we all go out and change our fan blade, just proposing a potential upgrade when doing maintenance.

    Hope this helps.
    Very interesting, does it fit correctly in the 540i shroud?
    E85 fueled, Eaton m112 supercharged 4.5L M62TU, TTV racing flywheel, Spec stage 2+ clutch, 88c thermostat, eibach sway bars, wavetrac 3.15 lsd, m5 steering box, Quantum 340lph fuel pump, Dinan camber plates, some powerflex bushings, Supersprint headers, M5 cats, 2001 gas pedal upgrade and many other things done. all diy by me

  17. #17
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    I like the ring blade design - eliminate the blade tossing possibility. Is there some advantage to tbe other visco clutch or is that just needed for bolt up compatibility purps? Im sure that S blade is quieter although usually S=quieter and flat=moves more air.
    2003 M3CicM6 TiAg
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  18. #18
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    Same dimensions and offset of stock fan, fits in stock shroud on both e31 with M70 and e39 with M62tu. I will try to post photos tomorrow.
    Last edited by bdiefAZ; 01-13-2019 at 01:57 PM.
    Regards,

    Brian
    Cave Creek, AZ

  19. #19
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    Quote Originally Posted by bdiefAZ View Post
    Same dimensions and offset of stock fan, fits in stock shroud on both cars. I will try to post photos tomorrow.
    +1, looks like a neat mod. Might have to investigate it for my M5.
    Nate J.

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    Subscribed

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    Ditto

  22. #22
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    I think the OP is stuck at the sub atomic level with Ant Man. He hasn't even logged on since he made his statement. Hopefully the Avengers can bring him back... Sheesh.
    I do not believe in a risk free society where the thrill of living is traded for the safety of existence. Nick Ienatsch

    The law does NOT determine "right" from "wrong". They are unrelated.

    If you put cheap parts on your car, you will soon have a cheap parts car.

  23. #23
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    Here are some of the modded fan pics on the e31 M70 car. The fan has the same clearance as before and has the same diameter and offset from the water pump as stock.

    IMG_3713.jpgIMG_3715.jpg

    Here is a photo of the M62 Tu e39:

    M62 Tu fan upgrade.jpg
    Last edited by bdiefAZ; 01-14-2019 at 06:34 PM.
    Regards,

    Brian
    Cave Creek, AZ

  24. #24
    geargrinder's Avatar
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    Hmmm. Looks close to the motor to me. Not like that's a problem, if you say it's good I believe, just looks like might be less deep in the shroud. Well,could be a prob for a blower kit car that already needs to uses the extender part to get the fan past the belts and whatnot. But seems like a cool parts bin upgrade for stock motors.
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  25. #25
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    Does anyone know why the M5 and 540i have different part numbers for the fan clutch? Different cooling system operating temps?
    Nate J.

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