Hello all,

I recently purchased a 97 Dodge Van 2500 Regency conversion for an incredible price. The van is in great shape but there are a few things that need attention.

A/C blower resistor: When we bought it this past Saturday, the A/C only worked on high. Thanks to this forum I new it was the resistor. I replaced it last night and the blower now works on all speeds. However, the connector that plugs into the resistor is melted on one side. It looks like it took a very large amp draw (maybe this happened when the resistor failed). Does anyone know where I can find another connector that I can splice on? I don't want to have to replace the whole wiring harness.


Fan clutch (I think): When accelerating there is a loud noise under the hood that sounds like a prop plane. From my reading I believe I need to replace the fan clutch. In the Haynes manual it said when the engine is off the fan should spin freely. When I checked it, I could turn the fan by hand, but there was some resistance. When they say "spin freely" how "loose" should it be?


Side mirrors: These guys seem to be a bit loose. They will fold inwards a bit at highway speeds. I took the plastic cover off and saw a bracket with 4 star head screws holding the mirror on. Everything was tight and I could not figure out how to prevent them from turning too easily.


Steering: The steering has a bit of excess play in it. Also when turning the steering wheel does not recenter. I have read here somewhere that I should check the idler bar and maybe the steering gear. Are there any other suggestions? I plan on looking at this on the weekend.

Entertainment: This van has 2 TVs in it. One in the overhead area just behind the front seats and a smaller one for the game system on the ceiling in front of the back seat. These are older tube TVs and I would like to replace them with larger LCDs. I was thinking of using standard LCD TVs or computer monitors and use inverters to power them. How do I determine how much amp draw is too much for the battery and alternator on the van? Also, is there a site or forum that discusses van entertainment centers? I have looked but can't find any.


Gas Mileage: This van has the 5.9l V8, which I know is not going to have great gas mileage. That being said, what can I do to maximize the mileage?
Would things like a K&N filter, or larger air intake tube help?


Thanks for helping. I have already received a lot of help just from reading through this forum.

 

You can get a speed resistor repair pigtail from the dealer (about $60). Ask for part #5019941AA

 

If your steering does not re center itself, It is likely the PO tightened the steering gear in an attempt to remove the play. The PO tightened it too much. The steering coupler is usually responsible for a lot of slop. I replaced mine with a U joint from Flaming River. The Idler arms are prone to wear and will cause excessive slop.

The side mirrors screws might seem tight, but could just be frozen. Try removing them entirely. You can pull the mirrors out from the top. If you still cannot tighten them enough, try cutting up an aluminum can and wrapping that around the shaft and re-inserting.

I used to have a 5" crt tv. It drew 1.4 amps. I now have a 7 inch LCD tv. It draws 0.6 to 0.7 amps. The bigger the TV the bigger the amperage draw, and at some point in size, the LCD's draw more power than the CRT TV's do.

You can get 12 volt TV's up to a pretty good size, just not any well known name brands.
If you do choose to go the inverter route, The inverter should ideally be close to the battery over fat cables. Use an AC household extension cord. DC current and long distances from the battery cause too much voltage drop, and the inverter will sense this and turn off. There are 2 types of inverters. Modified Sine Wave, and true, or Pure Sine wave. The true sine waves cost 3x as much, but put out very clean electricity. Some electronics do not like MSW inverters, like some power tool battery chargers, and some cell phone chargers. They might operate for a little while before burning up, or fail instantly. Some devices with electrical motors will overheat, and some devices with clocks might run fast or slow with a MSW. MSW can also cause electrical interference on analog TV stations, or cause any digital ones broadcast in the channel 7 to 13 range to drop out. MSW can also cause any speakers to buzz at 60 hertz, even if they are not hooked to the inverter.

The alternator will not have any issues powering your entertainment system. If you are idling at night, with the lights on, and the blower motor on high, then it will likely not be able to keep up, but a healthy battery should still be able to keep up for 4 or 5 hours of this abuse before the engine decides it does not like the low voltage.

You best bet for gas mileage is to keep it in top running condition, keep the tires properly inflated, and just slow down. Accelerating slower, driving slower, and anticipating red lights and the motives of the moronic narcissistic drivers around you can improve mileage by 20% or more. All synthetic lubricants might help slightly, but probably not enough to offset their cost.

It is my opinion that the only way a K&N filter will add to mileage is if the paper filter it replaced was clogged. Many have issues with K&N not filtering properly, and claim it is better to use a paper element, and change it more frequently.

The only realistic mechanical way to add mileage is to replace the belt driven fan with an electric one, and if your fan clutch is broken, now would be the best time for that upgrade. Keep in mind the fans can draw upto and over 25 amps, and it takes one engine horsepower for the alternator to produce 25 amps.

 

I just checked the local dealer for a fan clutch and they want $324 plus tax. When the local part stores want around $60.

Where can I get more information on what is involved to convert to an electric fan?


I am thinking about putting a 22" LCD TV in the van with an xbox. These will mostly be used while traveling. I don't think we will use them much while the van is parked. I have read other places that people are adding second batteries for accessories, so it made me wonder about the limitations of electronics.

 

The addition of second batteries is more along the lines of Isolating the engine battery for starting purposes only, and using the second(house) battery for powering those items needed when the engine is not on. If you never plan on using the electronics with the engine off, you do not need a second battery.

One should only goto the Stealership if one cannot find the parts elsewhere. I'd use them to get the correct part number, then look that up online.

There is probably many threads about converting to an electric fan, if you do a search.