97 dodge grand caravan cooling fans stoped working i changed the thermostat and flushed radiator also waterpump 4 months prior to all this i have good power to sensors and and also i checked fuses they are all good and relays, so i connected them to direct power and they turn but not when on the van
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There are two possibilities, one is the thermostat. Many people remove them which spoils the whole heating / cooling system. Since you changed the thermostat, I would check the heater valve on the heater which allows the hot water to circulate through the heating system.
It may be necessary to remove the heater box and flush the heater core since you talk about a lot of rust, which could have clogged the heater core and / or the pipes leading to the heater.
Couple of other items to check:
A) radiator cap - it might be weak and not holding pressure
B) thermostat in upside down - (not implying but it does happen)
C) blown head gasket
D) Fan belt slipping past waterpump - glazed
It sounds like you did everything, just back track over everything
What engine? i'll assume it's a v-6 is the radiator/coolant level proper? is the belt on the water pump? when it's running or idling before it overheats or as it's getting hot does the engine cooling fans come on? if you stand in front of the van at grille you will hear fans start up and run as it gets to >215*f or you should. if you don't it probably is the fan relay as these are common to go bad. it's a little electrical assy. located on the left side of the radiator shroud/support area best reached from underneath. they are not cheap and they are kind of hard to see and get to. if all the above is working your thermostat could be stuck shut and you'll need a flush and thermostat change.
IF COOLING FAN STAYS ON WHILE CAR IDLING AND DONT TURN OFF YOUR ENGINE IS RUNNING A LITTLE HOT.YOU COULD PARTIALLY CLOGGED RADIATOR OR ENGINE BLOCK PARTIALLY STOPPED UP ALSO THE THERMOSTAT NOT OPEN ALL THE WAY.HAVE VECHICLE SCANNED TO SEE WHAT COOLANT TEMPERATURE IS IF HOT.HAVE RADIATOR SHOP PRESSURE TEST COOLANT SYSTEM AND FLUSH OUT RADIATOR AND ENGINE BLOCK CHANGE THERMOSTAT.
Change your thermostat before it sticks closed completely. Sticky thermostat is usually the cause. Another possibility is that your radiator fan temperature switch is going bad. This is usually located next to the upper radiator hose at the gooseneck on your engine where the thermostat is located.
Have someone flush cooling system & check condition of rad for debris in front of rad & blow or spray it out as necessary. Next time it runs hot, turn your heater temperature up high, blower fan on high, and see if gauge starts to come back down a little. If it does, my guess is your rad needs replacing, or at least consider trying a good reverse flushing of the system first, then rad.