Not sure how it happened exactly, but it ruined my radiator. The whole front clip, radiator mounts and i guess front body mounts moved back. I had about a half inch clearance between the fan and radiator. I pulled the front junk forward as far as i could tightened the bolts. I replaced the radiator and fan clutch, but I still dont think there is enough clearance, just less than an inch i think. any one had these problems, and how do i make more room?
thanks

 

I have had my engine fan hit the radiator twice. Both times in 4wd, both times in soft sand, the truck started to buck and bounce, in the middle of nowhere, of course. The second time it pulled chunks out of the rad. 1 1/2 day field repair. You have a 1st Gen, so your set up is probably different, but this is what I did to prevent it from happening again. You moved the front clip, I moved the whole drivetrain back as far as it would go. Under my truck, on the transmission mount, there is a slot in the mount that will allow you to adjust the drivetrain. I added large, very tight, nylon straps, a leash of sorts, that prevents the drivetrain from lunging forward if the truck starts to bounce and buck again. I replaced the motor mounts and added a large "washer", 3/16" thick x 4" dia on the front side of the mount. This prevents the rubber interior of the mount from "wrapping" around the center bolt when the drivetrain lunges forward. It may be overkill, but I have peace of mind. With this setup, I have had no issues at all, and I have bounced and bucked (not that I like to) the truck since.

 

A broken or really worn motor mount can cause this to happen also.

 

I checked the motor mounts, and they looked good. I can't imagine that much forward movement, an inch or so, from bad motor mounts. the tranny and transfer case are tight, and those mounts appear tight also. the only movement i can detect is in the front mounts. and like i said i pulled the front as far forward as i could, but still not as much room as i think should be . does any one know off hand how much clearance should be between the fan and radiator?

 

Yeah, I still can't imagine all that metal moving that far forward either, but it happened, twice. You really can't see if the motor mount rubber is in good shape or not unless you remove them, and it is not that hard. Apparently the forward movment happens a lot, bucause racers use the restraining straps often. My fan clutch is 1 1/2" from the fan, it used to be closer to 1".

 

The trans mount is the usual cause of the fan getting into the radiator.

 

My OEM fan blades developed some cracks where they connected to the fan hub and just before the blade(s) twist. Chawed my radiator to.