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Issues:
1) I have had a low growl noise the last few months at start up, sometimes a short duration & sometimes a longer duration. Sometimes it does it, sometimes it doesn't. I seem to remember it doing the same thing last summet but never thought much of it until my next item discovery last week.
2) Pulled the trailer to Yellowstone last week. On long pulls, the fan seemed to be working as designed variating between speeds as required for cooling....then I noticed a high pitched squeal when I had my window down pulling a hard long hill (east bound from Ennis, MT to Virgina City, MT). It seemed to apear at 2,600RPM+. It sounds like a slipping belt, but not consistant - squeak, sqeeeeak, squeak, squeak, sqeeeak. Back out of it a little and let the RPMs drop some an the sound goes away, get back into it and pick the RPMs up agaun and it comes back. The belt apears to be just fine.
So, I thought that maybe these two things might be related and the fan clutch could be going south. I thought I would check here before I take it to the dealership. Is the fan covered on the 5 year/100K?
Tensioner is covered as are idler pulleys, its possible that your fan is making so much noise from a low coolant level. Check level and make sure, also check for residue indicating its venting. The belt will not be covered but the fan clutch is also covered like the tensioner and idlers for 5yr/100000
I was thinking about this some more this morning. One guy said that he did replace the belt, but he had a "Goodyear Gator" brand belt put on instead of a stock Ford part and that did the trick for him. There was also one who said that his dealer sanded all of the pulley surfaces with a fine grit sandpaper to roughen them up.
This is not a new problem. They had the same issue with the early 7.3's way back when. Ford has a TSB out on that one and the resolution was a different fan belt (Ford part) that had a different rubber composition.
I'll try the Goodyear belt before I start towing again later this year.