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el aux fan in 2002 G500
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Posted 5/10/2014 11:08 AM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
el aux fan in 2002 G500

can anyone help with a disassembly pdf for the 2 aux fans on a 2002 G500

one of mine makes horrible bearing noises

maybe I can revive it with new bearings

but I have no clue how to get those monsters out
#221778
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Posted 5/10/2014 11:24 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: el aux fan in 2002 G500

4x4abc - 5/10/2014 11:08 AM

can anyone help with a disassembly pdf for the 2 aux fans on a 2002 G500

one of mine makes horrible bearing noises

maybe I can revive it with new bearings

but I have no clue how to get those monsters out


Are you talking about the two in front of the radiator? If yes, send me your VIN; and I'll find it in the WIS.

I did it in my 2000 G500, and don't remember it being all that difficult. You do have to remove the grill.
#221779 - in reply to #221778
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Posted 5/10/2014 11:34 AM
djdinaz
Extreme Veteran




Date registered: Jun 2007
Location: Arizona
Vehicle(s): 03 G55
Posts: 439
300
RE: el aux fan in 2002 G500

Here's the WIS for removing them.

Once you get them out, you'll see that the small motors are stamped together with no intention of ever being serviced.

The G-specific aux fans (A0015001593) are ridiculously overpriced ($428 to $575 each), but, they're exact same size and rating as those found on the CLK (RH A0015001393, LH A0015001293) ($189 to $254). The RH CLK fans have a longer pigtail connector than the LH. I picked up a pair of RH fans off of eBay for under 300, cut the pigtails to the length of the G fans, soldered on the G connector, and they've been fine ever since.



Attachments
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Attachments AR83.30-P-5600G.Remove and install additional fan.pdf (519KB - 63 downloads)
#221780 - in reply to #221778
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Posted 5/10/2014 1:01 PM
Roly
Elite Veteran




Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
500
RE: el aux fan in 2002 G500

I repaired a set of fans which had been driven into mud and then left to dry. Both were solid stuck. The motors are not designed to be serviced but can be dismantled with a bit of patience. Clean, and oiled and they were good again. Mind you, they are spares and haven't been used in anger. didn't try to remove the bearings, but anything is possible with some time and a workshop.
#221781 - in reply to #221780
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Posted 5/10/2014 1:02 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: el aux fan in 2002 G500

They definitely aren't built to be repaired.  The brush wire on one of mine failed and I had to Dremel a window into the end of it to get to the wire.  You might be able to puddle a bit of oil on each end and get it to soak in. 
#221782 - in reply to #221778
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Posted 5/10/2014 1:27 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
RE: el aux fan in 2002 G500

for Dutch: WDCYR49E42X128101
#221783 - in reply to #221782
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Posted 5/10/2014 2:09 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
RE: el aux fan in 2002 G500

Thanks Darren, I will get the CLK fan and see if I manage get a temporary fix (my next parts delivery to Mexico is 2 months away)
#221784 - in reply to #221780
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Posted 5/10/2014 2:26 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: el aux fan in 2002 G500

4x4abc - 5/10/2014 1:27 PM

for Dutch: WDCYR49E42X128101


Thanks, but no longer needed; since djdinaz posted exactly what I would have posted. He was quicker on the draw.

Hope you get it worked out.
#221785 - in reply to #221783
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Posted 5/10/2014 3:11 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
RE: el aux fan in 2002 G500

I'll keep you guys posted

don't feel like working on the truck though
#221786 - in reply to #221785
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Posted 5/11/2014 1:10 AM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3006
2000
Re: el aux fan in 2002 G500

These fans are the same on all G500's i swapped the fans from my '02 and '99 to double check and they were exactly the same. You can disconnect the noisy one and still use the other.

Edited by otiswesty 5/11/2014 1:11 AM
#221787 - in reply to #221781
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Posted 5/11/2014 8:08 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

Eric,

that was my plan B
#221791 - in reply to #221787
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Posted 5/19/2014 11:00 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

OK, got the noisy fan out

what a frustrating job!
in German: "Für einen, der Vater und Mutter erschlagen hat."
"for someone who killed mom and dad"

not at all as described in the WIS
you have be very creative to get the fan out - unless you want to do major surgery

drowned the motor in oil for an hour
then spun it - first slow then faster

I might get a few more weeks of life out of it



(job hell.jpg)



(fan in bucket.jpg)



Attachments
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Attachments job hell.jpg (396KB - 0 downloads)
Attachments fan in bucket.jpg (316KB - 0 downloads)
#221963 - in reply to #221791
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Posted 5/22/2014 12:39 AM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

so, everything is back in place

both fans run

the annoying bearing noise is gone

I hope it buys me enough time until the new fan arrives



(listo.jpg)



Attachments
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Attachments listo.jpg (330KB - 0 downloads)
#222006 - in reply to #221963
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Posted 5/22/2014 12:47 AM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
2000
Re: el aux fan in 2002 G500

What about the other one?

Just a bit more preventative maintenance before the sun heats up the day.
I noticed the daily temps are in the mid to upper 30's Celsius.....

Karl
#222008 - in reply to #222006
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Posted 5/22/2014 12:56 AM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

Karl,

the left unit spins so super smooth that it would have been a shame to bathe it in oil like his sick brother
#222011 - in reply to #222008
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Posted 9/3/2014 8:00 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

So, an update.

The oil bath bought me some considerable time - 3 months!

just last week the noise came back
had the new fan sitting in the garage - ready to go in
bought it on Amazon for $54
even thought the site states that it would not fit the G500, I had information saying otherwise

put it in today - fits perfectly
one of the fan blades carries a balance weight - cool detail
used the plug from the old unit since the new plug was a little too "Chinese"
cable was a bit long, but longer is always better than too short
no part numbers in the cast as the original, for the price I could care less
runs quieter than the original




(amazon.jpg)



(old-new.jpg)



(part number.jpg)



(no part number.jpg)



(no fit.jpg)



(perfect fit.jpg)



Attachments
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Attachments amazon.jpg (105KB - 0 downloads)
Attachments old-new.jpg (389KB - 0 downloads)
Attachments part number.jpg (184KB - 0 downloads)
Attachments no part number.jpg (188KB - 0 downloads)
Attachments no fit.jpg (197KB - 0 downloads)
Attachments perfect fit.jpg (233KB - 0 downloads)
#223797 - in reply to #222011
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Posted 9/4/2014 12:06 AM
MiN
Extreme Veteran




Date registered: May 2006
Location: Alpujarras, Spain
Vehicle(s): No cars, at all.
Posts: 555
500
Re: el aux fan in 2002 G500

Harald, thats a good find.

Having done this a few times, there is a simple way to remove the fans. Once you've removed the cross member above the fans, remove the 2 nuts holding the left side of the power steering pipe, remove the 6 nuts holding the radiator channelling and the 6 bolts holding the fan housing to the radiator channelling. Once done you can lift out the whole fan shroud with both fans intact. You can then remove the fans individually.
#223803 - in reply to #221778
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Posted 9/4/2014 12:18 AM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

done exactly that, Mike.
#223805 - in reply to #223803
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Posted 9/4/2014 12:40 AM
MiN
Extreme Veteran




Date registered: May 2006
Location: Alpujarras, Spain
Vehicle(s): No cars, at all.
Posts: 555
500
Re: el aux fan in 2002 G500

Ah ok. We must differ on what constitutes a "Für einen, der Vater und Mutter erschlagen hat." I guess the frequency of doing it lessens the frustration involved.
#223807 - in reply to #221778
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Posted 9/4/2014 4:03 AM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
Re: el aux fan in 2002 G500

well, my German wurst fingers did not make things easier the first time around - too many tiny nuts and bolts (8 and 10 mm)
and yes, it was easier the 2nd time around
#223810 - in reply to #223807
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