Contour Enthusiasts Group Archives Forums General Troubleshooting Engine Cooling Fan Problem

I have a 1995 Ford Contour LX, V6 24 V automatic. I ran a couple of errnads this morning and came home. After I turned off my car, the engine cooling fan continued to run. It continued running for at least 20 minutes, close to half hour. I finally checked the manual to check and see what fuse/relay it is (R2) and pulled the fuse. Finally it stopped. I may have answered my own question. But, I'll ask it anyway. Is this a bad relay? Has this happened to anyone else? My engine cooling fan has never done this before. Where can one of these relays be purchased on a Sunday? I would assume it's a Ford only part. Or the junk yard. What do you guys think?

My guess is that you may have a stuck relay (relay contacts may have welded themselves together). First check to verify you don't have primary voltage to the relay trigger circuit. I not, then the relay contacts may be welded or heat fused together. The reason I say this is because those cooling fans (and/ or install location) on the '95 2.5L are faulty. I've went through 2 new fans on mine (I just had the second entire dual fan unit replaced not too long ago. What happens, is the fan unit is in such close proximity to the hot exhaust manifold, plus with all the normal heat coming off the radiator as well, is getting the fan motor too hot. And eventually, the fan motor bearings fail and one or both of the fans gets really hard to turn, which puts more load on the fan's motor, which makes it draw more current through the wiring harness in the fan circuit. Since this had burned down a number of Contours throughout time, Ford (probably under some public and legal pressure) decided to create a recall for the fans, and while dealers would be in there replacing them, they would also install better circuit protection (an inline fuse and fuse holder on fan shroud for fan circuit). This will avoid any cars harness's from lighting up anymore. If your fan doesn't show signs of a bad fan motor, then Ford will not replace the fan unit, but they WILL install the fuse protection to avoid any electrical fire hazard.
So, providing that you've not had that inline fuse installed yet (as per Ford recall) then my guess is that your fan circuit has at some point reached maximum current handling, which maybe have glued (heat fused) the relay contacts closed. (By the way, this inline fuse holder installed under recall, is not the same fuse that goes in the fuse panel.) Next thing I wound up seeing on mine after that was smoke coming from fan motor (I was lucky my car didn't burn down when that happened). You'd think they would have came with sufficient fuse protection originally from the factory, if the engineers had been doing their jobs. I kinda wonder about these Ford guys lately. Anyways, hope this helps

Wow Josch! You sure have your ducks in a row! As do I. Last year, on July 12, 2001 at 145,444 miles, I had the recall work done that you mentioned. The engine cooling fan was bad, along with the fuse, in which Ford replaced under Recall 00S44. They replaced the engine cooling fan and fuse. Funny, the warrenty I have on their work expires at 12 months (now over 12 months), or 12,000 miles. In which I have exceeded both.

I have just tried to put R2 back into the socket in the power distribution box and the cooling fans come on right away. In which I would think you are right that the relay has melted together. I will have to wait until tomarrow when Ford opens to buy another relay. In the meantime, I guess I will have to stay close to home, or remove the relay everywhere I go. I am sure that'd be funny.

ContourGirl,

Check your regular parts store as my local Advance Auto Parts had the correct relay for my 87 LeSabre, $9.95

Can't hurt to check another source that is open on Sunday.

TB

We metered the relays R2 and R5, and they both are good. Next suspect: Engine cooling temperature sensor. I am finally able to put the relay back in the car without the fans coming on. I will watch this closer tomarrow to see if this continues and also look to see how much the sensor costs.

Not sure what you mean by metered the relays, but I don't see how sensor would keep fans on since it feeds PCM, which is unpowered with key-off.
If it happens again pull fan fuse.

Edit: See later post.

What happened was, when the relay was in the distribution box, the fans kept going, even when the car was off for an hour or more. When I pulled the relay out, they stopped, when I put the relay back in (while the car is off) the fans started right back up again. After about 1 hour, I drove 10 miles to where I know a couple of guys who work on cars. That's when they metered the relays to see if the relay was stuck closed. When we metered it, the relay was open. I am not sure what else would keep the fans on, after I turn the car off. After about 3 hours yesterday, we put the relay back in the car, and the fans haven't done this again (stayed on after turning off the car). Since then I drove home and to work this morning.
Strangest thing I have seen my car do yet.

Check the voltage of your battery/charging system. If your voltage is low, you could be drawing more current to do the same work, hence the stuck relay.

Or the relay could be marginal now, and it merits replacement, as it is now suffering only intermittent failures.

TB

Sorry, I said fan fuse but I meant to say PCM power relay fuse f9, engine compartment fuse box. If fans are staying on with ignition off, then pulling this fuse ensures cooling fan relay coils have no power. Therefore, if fans remain on you have potential stuck relay contact (r5-lo speed) and relay would have to be pulled to shut them off, pending replacement.

The fan fuse - f2 60amp is unfortunately not a push in type.