1. what temp should the fan engage at? mine used to stay silent until well over 200*, but last night it was engaging around 190* and staying on longer than it needed to, pretty annoying around in town.
Fan engages on air temp, not water temp... important. Why? The air going through your rad picks up heat, then hits the thermocoil at the face of the clutch, causing it to engage. Dirty rad, poor airflow, etc can cause the fan clutch to engage at the wrong time (or not engage at all). If you don't get airflow, your fan also won't DISengage, because it can't cool off. Most often seen when vehicle is not moving, or pulling really heavy in slow traffic.
2. should the fan spin freely when cold? mine will spin maybe 25* before stopping, there is a lot of resistance.
Fan is on a viscous clutch, so no, it should NOT spin freely. The fan clutch never completely "disengages".
3. with the Duramax upgrade, I'm looking at the Big 3 of the 6.5s, (SS, Heath, KD) and there are differences between them all. The heath system uses the stock calibration fan clutch and the dura fan, but is 300 bones.
You better phone Bill Heath and talk about that... mine is a Heath, and it kicks in at a lower-than-stock temp. It is also a higher torque-transfer clutch, meaning that when engaged, the fan spins at closer-to-engine-rpm than the stock version. More info on clutches found at
http://www.haydenauto.com/ or you can see a write-up at
http://www.oliverdiesel.com/products/haydenfanclutch.htm
The SS system uses a lower temp calibration and the dura fan, for 189, and
Also a little fishy... the SS sells the stock clutch, not a special-calibration one.. You can get the same one from your dealer.
the KD system wants to reuse the steel fan, which by all acounts is a bad idea...
Kennedy uses a special-calibration clutch which kicks in 15*lower temp, but also tends to stay engaged too much when normal driving. Turbine Doc has had the Kennedy system and reports that he took it off because it was engaged too often, robbing fuel mileage and power (plus being noisy!) in favour of the Heath clutch and fan.
Kennedy recommends that users also get his special 9-blade steel fan, which does move lots of air. Don't know where you got the notion that this was a bad idea... you can also go to GM and buy a 2000 6.5 9-blade steel fan. They move as much air as the 9-blade composite duramax fan, which is more than your stock 6-blade steel fan.
so this is pretty much to those with the dura fan upgrade... who did you buy from, why, and what differences did you notice?
Mine has a Heath SD clutch and I kept my stock 6-blade steel fan. I pull reasonably heavy (9800 lb), in big mountains, with hot ambients (ie: through western Washington, Oregon and in Alberta/BC. No problems since upgrading my fan clutch, thermostat (Genuine ACDelco only!), cleaning my rad (properly!!), and installing a TCC lock. Before doing that, I overheated just THINKING about pulling the trailer!!