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I installed the Geo temperature switch this evening, with a little creative wiring. I didn't want to remove the original plug, in case I wanted to go back to an original style switch in the future. Some of you guys probably already figured this out, but I thought I'd at least post my process in case it helps some of you...
First off, I noticed that the original switch connectors were about the same size as some bullet connectors I had, so I worked backwards from that. You can see the bullet connector on the left, original switch, and the new Geo switch.
The area inside the Geo switch is so cramped that even two small blade connectors didn't fit well. They DID fit but were touching, which is not a good thing. So I took the blade connectors and trimmed back the plastic sheath, but left enough to protect the crimp area.
I then soldered a 3-4" length of wire onto the BLADE part of the connector, and then protected using some shrink tubing.
On the opposite side, I soldered two of the large bullet connectors, and of course... more shrink tubing.
The crimped part of the small blade connectors slid over the Geo switch just perfectly!
So I have this:
Electric taped it really well:
The bullet connectors fit into the original plug really well. They seem nice and tight and don't move around so I assume they're good. Not sure how I'm going to protect them from the elements. And I may have to zip-tie the wire away from the fan blades.
I assumed it was bad because the PO had hard wired the fan directly to the battery. In all honesty, I figured that while I was in there, radiator out, timing belts, replacing o-rings, etc., I might as well bite the bullet and put in a new temp switch. Then I saw the "how-to" and got intrigued.
