I think I spelled that right. Anyhow the fan shroud on my 4runner decided to break away from the bolts. On further inspection the top two bolts were the only ones holding in on but the shroud broke away for them.

So I moved them (bolts) down to the lower bolt location which are a little banged up to. Any how if I was to get an oversize washer and bend it in such away as too go around the broken area. Would that hold it or should I just replace it (I'm NOT removing it).

 

just replace the shroud. They are pretty cheap from the dealer, and you wont have to go modifying and screwing with the plastic. Typically, those mounts crack for two reasons:

1. Old plastic gets brittle and breaks
2. Over tightened bolts squeeze the plastic out, and eventually it breaks

 

This would be an excellent opportunity to do the electric fan mod. You would need to remove the shroud and the clutch fan as part of the mod anyway. Do a search on Taurus fan or electric fan mod. I did one on my Gen 2 and it worked great. Looking to do it as well to my 98' as soon as I find a another high end 2 speed fan that is close to fitting my radiator.

If you don't desire to mod the engine compartment, then yeah, you NEED to replace the thing. Cheap from dealer and cheaper still at a local wrecking yard.

 

Does our fan shroud play a big part in directing air for cooling or is it just an idiot proof way of keeping your hands out of moving parts? I didn't think it did so I left mine off when I changed the radiator. I always have a hard time cleaning mud out of the radiator fins after a muddy wheeling trip. Its winter right now so i haven't had any overheating at all...im just wondering how it's going to act in the summer.

 

yes the shroud helps pulls the air through the radiator. with no shroud the fan tak air from infront of the radiator the the shroud in place it pull air through hence cooling the fluid.
in the summer time if you are parked or at a stop light your temp most likely will climb up .

 

I kept the shroud just in case. I want to see if it's going to make a difference.

 

shroud makes a big difference for cooling. I recommend the electric up grade, I'm impressed with mine and got it for a good deal to boot.