Hi Todd,
Some updates on the Exfan/HD clutch (Motorcraft YA220 and Hayden2794). Beautiful 11 plastic blade fan. Cost is reasonable at $47+$59 from Amazon.
Yes I have the big rushing sound on cold startup. Lately it sure is quiet at anything above 80F. During normal driving the clutch seldom engages (never?). Even towing up the CO mountain passes it stays quiet (much cooler ambient). It does come on when driving in high range following an RV at 10MPH on the passes.
Its another story in Baja. Always quiet (reasonable warm weather) until I hit the sand wash and when the clutch engages I get a big cloud of silt under the rig and thru my hood vents. Not to bad because I am in a closed rig. Would not be so good in an open rig.
Anyway I wish I had this setup on the EB, but I still have the Mustang setup and Explorer is not an option at this time.
How I got up to speed was a thread elsewhere by a radiator shop owner who had an Explorer come in one day. It got him thinking and experimenting and he tested with an anemometer various fans and clutches ending up with the pair noted. The Explorer fan has to have a shroud to accepts the 18" Ex fan. That means a centered shroud that has a 19-20" opening. Result for a EB is make your own since I could not find one to buy. Anyway, my EB has the correct shroud but the wrong fan. Make your own Shroud from a Ford plastic one cut and reinforce with fiberglass to make it aerodynamically smooth. IMO, stay away for the metal fab shroud due to lack of aero internal shape.
Yes, I know all my testing is on the Jeep. Data is still good and agrees with the radiator shop guy. The Jeep cooling system (late model) has way more margin than any EB will have so be sure you understand that. Radiators & shrouds do mater.
Regards, PaulW