Some 2004-2007 E-Series 350/450, 2003-2005 Excursion and 2003-2007 F-Super Duty vehicles equipped with the 6.0L diesel engine may exhibit improper engine cooling fan clutch operation, due to its wire harness being cut by the rotating cooling fan. The harness may be cut because the molded-in retaining clip on the fan stator that secures the harness to the stator is broken or missing, allowing the loose harness to move into the rotating fan. Per Ford’s recommendation, if the harness is damaged or severed, replace the cooling fan clutch assembly. Carefully drill a 1/8-inch hole through the tab and stator. Hold the harness fully down in the stator slot while drilling the hole to assure that the harness will be positioned away from the fan. Install and tighten a screw to a value of 9 in.-lbs. (1 N-m). According to Ford, the job time is 1.5 to 1.9 hours.
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