Toyota Tundra Electric
Fan Kit; 00’–06’
#775 with Controls
#778 without Controls
REMOVAL OF EXISTING FAN AND SHROUD ASSEMBLY:
1. Make sure the engine is cool.
2. Disconnect negative (-) battery cable from battery.
3. Remove radiator cap.
4. From under the vehicle;
a. Remove skid-plate mounted to frame and front cross member.
b. Slowly loosen pet-cock to drain approximately 1 gallon of coolant. Note: Drain coolant
to a level below upper end of the radiator hose.
c. Remove lower section of the two piece shroud. It is held on by 2ea. metal clips and 2ea.
molded plastic hooks.
d. Remove bottom bolts 2ea. holding fan shroud to radiator side brackets. Save bolts for
installation of new shroud.
5. From top side of engine compartment, disconnect radiator hose from top of radiator and secure
it out of the way.
6. From the air ducting to intake manifold; remove bolt holding A/C return hose, then secure hose
out of the way (see Detail 1). Note: bungee cords or long zip-ties work well.
7. Remove coolant overflow hose from radiator filler neck.
8. Remove top bolts 2ea. holding fan shroud to radiator side brackets. Save bolts for installation of
new shroud.
9. Remove fan shroud by pulling strait up. Note: Be careful not to scrape against the radiator
core.
10. Remove clutch fan assembly by removing 4ea. nuts securing flange to pulley. Re-secure pulley
with washers of kit bag #13615 and previously removed nuts (see Detail 2).
Detail 1
A/C return line
Detail 2
Resecured pully w/ washer kit
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INSTALLATION OF NEW ELECTRIC FAN SHROUD:
You will want to “pre-wire” fan motor wires & Variable Speed Controller (VSC) to new fan shroud
before mounting to vehicle.
11. Careful planning will save time. Look at the wires
coming from the motors. The positives from each
motor will be connected together, as will the negatives. Drill a ¼” hole through the center brace in the
shroud to pass one pair of motor wires through.
(see Detail A).
12. Place both red motor wires side by side and
smoothly twist together. Completely insert pair of
wires into one end of a yellow insulated butt connector. Crimp connector to secure. Repeat with black
motor wires to another yellow insulated butt connector (see Detail A). Red motor wire is (+) positive
and the black is (-) negative.
13. It is easiest to attach the VSC directly onto the front
face of the fan shroud. Using the holes in the controller cover for a template, drill two 5/32” holes.
Secure the VSC with the two screws provided.
14. Drill two ¼” holes in the shroud where the thick
yellow & purple wires from the VSC will pass through
to the back side of the shroud (see DetailB&C).
15. IMPORTANT:
Insert yellow wire into the open end of butt
connector containing the two red motor wires
and crimp connector securely. Insert purple wire into the open end of butt connector
containing the two black motor wires and crimp connector securely. (see Detail C)
16. Mount bracket #77502 to driver’s side and bracket #77501 to passenger’s side of shroud. Use
the hex bolts and washers provided.
17. Lower shroud assembly between engine and radiator and loosely mount at top using OEM bolts
to original shroud mounting points. Note: Be very careful not to damage core.
18. From under the vehicle;
a. Attach bottom of shroud using OEM bolts to original shroud mounting points and tighten.
b. Reinstall protective skid plate.
Detai A
Detail B
Detail C
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19. From top side of engine compartment, finish tightening shroud top mounting bolts.
20. Reattach radiator hose, refill radiator with coolant, and reattach radiator cap.
21. Reattach A/C return hose to original mounting point.
22. Find the thick red and black wire in the kit. Determine the length needed to connect the red and
black power leads on the VSC to the battery terminals and trim appropriately. Crimp a large
yellow ring connector to the end of the black wire and connect to
the negative (-) battery terminal. Connect the other end to the
black wire on the VSC with a large butt connector (yellow sleeve).
23. Locate the fuse holder but DO NOT INSTALL THE FUSE UNTIL
ALL WIRING IS COMPLETE. Attach a large ring connector to one
end and a yellow insulated butt connector to the other end of the
fuse holder. Attach the ring connector to the positive (+) terminal
of the battery and connect the other end to the thick red wire
found in the kit. Determine the length of wire needed to reach
from the fuse holder to the red wire on the VSC and trim appropriately. Use a yellow insulated butt connector to connect this wire to
the red wire on the VSC. You may use the 2ea. small screws to
mount the fuse holder if desired.
24. Find a circuit in a fuse box that is “hot” only when the key is in the
“ON” position (example: “Radio”). Attach the included fuse tap to
fuse (see DetailD&E). Attach a blue female connector to one
end of the thin red wire (included) and connect to fuse tap. Determine length of wire needed to reach VSC and trim to appropriate
length. Attach a blue female connector to the end of the wire and
connect to terminal #9 on VSC.
25. On the top side of A/C compressor find a plug-in connector with 3
wires (see Detail F); locate the green wire w/ black stripe and
attach supplied thin green wire by way of a piggyback connector.
Determine the length of wire needed to reach from the piggyback connector to the VSC and
trim appropriately. Crimp a pink female connector at the green wire’s end and connect to terminal #8 of the VSC.
26. Locate temperature probe. Gently push
the probe through fins in radiator as
close to the upper radiator hose as
possible with ¼”-½” of the probe protruding out of the front of the core.
Install the rubber cap on the front side
of the probe (if possible). This will give
the VSC the most accurate engine
temperature reading. Determine length
of wire needed to reach VSC. IMPOR-
TANT: Strip the insulation on the temperature probe wires back about ½”
and fold wire on itself to effectively
double the thickness of the wire before
connecting pink female connectors.
Attach these wires to terminals #10 &
#11. Both wires need to be connected but it doesn’t matter which wire goes to each terminal.
27. If manual switches (Flex-a-lite #31148) have been purchased, attach them as follows. To override engine temperature to turn fans off, connect the switch to terminal #5 on VSC to send a
ground signal. To override engine temperature to turn fans on, connect the switch to terminal #6
on the VSC to send a ground signal.
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Detail F
Detail D
Detail E
Initial VSC Set-up and Adjustment
1. Turn ignition on. After 5-6 seconds, LED #4 should light up, if not, check to make sure that you
have 12 Volts at terminal #9 on VSC. The delay is to allow starter to start the vehicle without the
fans drawing any power.
2. With your engine running, engage the A/C. Your fans should come on and cycle with the A/C
clutch. LED’s #1, 3 and 4 should be lit when fans are running. If they do not turn on, verify that
the A/C clutch is engaged and make sure that you have the appropriate wire connected to the
correct terminal on the VSC. Shut off A/C and let engine continue to idle until it reaches normal
operating temperature. Verify that normal operating temperature has been reached by feeling
upper radiator hose. Hot water should be flowing through the hose into radiator.
3. Adjusting the VSC to come on at normal operating temperature is done as follows: Locate adjustment screw through center of cover. Using a small strait bladed screwdriver turn the screw to the
full clockwise position, let the vehicle reach desired operating temperature, then dial it back
counter clockwise just until the fans engage.
Note: Maximum rotation of adjusting screw is ¾ turn!
DO NOT FORCE ADJUSTMENT!
4. Once desired temperature is set, let engine continue to idle in order to make sure the fans will
cycle and maintain desired temperature. When fans are running, LED’s #1 and 4 should be lit.
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The Variable Speed Control has new features:
When you set the on Temperature, the fans will come on at 60%; this reduces the load on your
charging system. If the temperature rises, the fan speed will increase. If your set temperature
is 185 ° F, then between 185° and 195° the fan speed will increase from 60% to 100%. So after a
10° rise from the set point, the fans will be running at 100%.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E. Fife, WA 98424, Telephone No. 253-922-2700, warrants to the original purchasing user, that all Flex-a-lite products to be free of
defects in material and workmanship for a period of 365 days (1 year) from date of purchase. Flex-a-lite products failing within 365 days (1 year) from date of purchase may be
returned to the factory through the point of purchase, transportation charges prepaid. If, on inspection, cause of failure is determined to be defective material or workmanship and
not by misuse, accidental or improper installation, Flex-a-lite will replace the product free of charge, transportation prepaid. Flex-a-lite will not be liable for incidental, progres-
sive or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply
to you. This warranty gives you specific legal rights and you may have other rights, which vary from state to state. The Flex-a-lite warranty is in compliance with the Magnuson-Moss
Warranty Act of 1975.
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