I am working on sorting out the issues with Andrews Bronco before I send it off to 29 Palms, the SoCal desert where he be stationed for the next 3 years

I am down to just 2 items, both electrical in nature

#1 - his fuel gauge is not working. I have not even tried to sort this one yet but I am fairly confident that I can

#2 - the 30a fuse that powers the relay for the electric fans keeps popping. Like as soon as I turn the key on it pops. I put new junk yard fans in because the old set, only one side worked. It was fine around here but in the desert where 105* is a normal day, thought I should get them both spinning.

As you know, there is nothing original or stock under the hood. 4.9l inline six runs great, radiator and fans from a 2001 windstar v-6 mini van. Never had issues over heating. Re-wired everything from the front seats forward because he had cut, spliced, taped, zip tied, hacked and chopped dam near every circuit. Landshark was a huge help in that process and of course, Phill was our lead during the original build.

Power is from a key on circuit, fused to a relay that then powers the fans.

Now- if you have any ideas on the fuse issue, or the fuel gauge, I would really appreciate it, but not nearly as much as Drew will

I was able to work out my fuel gauge pretty easily. Just started at the dash and went from there. Could be a bad sending unit. I might be in the Ranch sometime Friday afternoon.

Did the fuel gauge work at all after the EFI swap?

30 amps sounds too small for dual electric fans.

If the fans are blowing the instant the circuit gets power, even when the truck is cold, there is a short to ground between the fuse and the relay.

I would scrutinize every inch of wire between those two locations first.

ETA: I agree with Viperwolf, 30amp is smallish for two fans. Are your fans wired through a thermostat switch or are they hot and "on" all the time?

The fans are wired to turn on with the key in the on position

So how big a fuse for dual fans? 50a? 60a? There is a 60a relay

Honestly Phil, I'm not sure about the fuel gauge. And Drew is currently doing "field training" so I can't even ask him for another week.

All wiring between fuse and relay and fan is brand new 10ga.

I will pick up a 60a fuse on my way home tonight and see if that helps.

Thank you guys a ton!

edit: Looks like I will have to switch locations to a maxi fuse from the standard ATO/ATC fuse, I looked online and looks like the largest std fuse I found was 40a. No big deal - I have plenty of room in the fuse box, just means opening it all up again. Not quite as quick a fix. Thanks again.

Yup

As the venerable Viperwolf said....

30a might be a bit small for dual fans

Routed the power wire to an open space maxi fuse, pushed in a 60a maxi and voila

Dual fans running and sucking clean air through the radiator like they were designed to do, better than hoped even. Sat there idling in the driveway for over 40 min, never got over 160* on the after market gauge.

After all that fussin, turns out it was a fairly easy fix.

Now fuel gauge tomorrow, hope it goes as well

Thanks Phil and Digger! Your advice was spot on