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Discussion Starter #1
So my radiator fan continues to keep breaking. I brought it to a mechanic and he replaced it and a month later the car was shaking again as I noticed the first time when the fan broke. I have just recently replaced the radiator fan myself and am trying to prevent this from happening again.
 

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How does it keep breaking? Are the blades breaking off? That's what would
cause it to shake. I had two break on me, but they were due to front end
impacts... The only other issue I had, was the intake elbow from the front
snorkel to the air-box came loose and hit the MAIN fan, but did not break any
of the blades, but a hole was cut into the tube from the fan outer ring...

I had two pieces fly off and they impaled the hood insulator:


Yeah...
 

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Discussion Starter #3
Yes the fan blades continue to break off at the very bottom and fly under my car while driving and eventually I will notice the shaking while sitting at a stop light. There is no sign of the blades hitting anything the only theory I have is that it gets very hot and cools down after a while and overtime they just get very weak considering the fan is plastic. After driving I have opened up the hood and felt the fan and yeah they should be hot I can understand but so hot that I cant touch it for more than a second seems wrong.
 

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They do not get weak due to the hot and cold... I had my TDI for
three years, and the fan blades only broke due to front end collisions;
the shock alone caused it. They never, EVER broke on their own...

I have a TSI, Going on 74,000 miles, turbo too, and the nothing has
broken.

My only other guess is, the shroud is loose, and you hitting bumps and
pot-holes cause enough shock to break a blade... No fan blade should
just break for no reason, hot or cold... You have a problem somewhere,
probably happens when driving...

EDIT:
Oh! I forgot! Does your fan shroud have the four rubber flaps in it?
IF so, are any of the flaps MISSING? TWO perhaps? There's what ripped
your fan apart. I forgot, one of those rubber flaps fell out, and broke my
AUX fan the 2nd time... I almost forgot about that!!!

THIS:

Four rubber flaps above the fan shroud = four times your fan can be broken...

SOLID shroud:

THIS one, does not have the rubber flaps...
 

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Discussion Starter #5
So the radiator fan in my car looks a bit different that looks to be the newer fans or atleast it looks to me like my fan for the A/C.. it seems the link of my photo is not working its ridiculous I need more posts to share links but the radiator fan is just the fan alone it does not have an outer black cage around it if you could keep in mind this is a 2003. thanks!

-Tyler
 

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So the radiator fan in my car looks a bit different that looks to be the newer fans or atleast it looks to me like my fan for the A/C.. it seems the link of my photo is not working its ridiculous I need more posts to share links but the radiator fan is just the fan alone it does not have an outer black cage around it if you could keep in mind this is a 2003. thanks!

-Tyler
Was never in mind, because that info was not provided in the first place...
Plus, I am just using examples, that was what MINE looked like... VW uses
the same assembly through a wide span of years, makes, and models...

VW doesn't put cages around their fans anyway, they are 100% exposed.
You are mistaking the cage for the shroud. Aftermarket, universal fans,
usually have the cages around the back of the fan.

Do yours look like this?


THIS?


Here are the parts and diagrams:
http://www.keffervwparts.com/Volkswagen_2003_Passat/Belts-and-Cooling.html
 
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