I am on my 3rd fan clutch in less 2 years on my 05 (5.4) I am now guessing its something beyond the clutch, but not sure what to look for.

The first one was a few months after I purchased the truck with 96K on it, it was hit and miss but usually would roar like a kenworth, so I replaced it. (with a motorcraft one) It worked fine for about a month & slowly started roaring again, mostly on startup but then would quieten down and operate normally. It got continually worse so I replaced it again (under warranty) This one worked like it should for almost a year but has been gradually getting worse & its January in northern canada.. the fan clutch should not be engaged, & seeing as its almost constantly engaged it takes a long time for the truck to warm up. I am not sure if I've just had a bad run of clutches or if its the water pump, These trucks dont have a fan clutch relay right? I didnt see one on mone. Any suggestions would be appreciated. I am aware I could switch to an electric fan, but the time and money isnt there & I would like to figure out whats actually going on.

 

My 06 roars a lot when cold, then settles down. Bought the truck used so I'm not sure if the original is still in it. I've thought about taking the fan off in the winter to see if MPG improves. If it's significant I may switch to electric.