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I never hear the fans turn on
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Why don't you first rule this out as a problem. We have to make sure these are working properly first. Also look at JIMF's Cool Harness. It will kick in the fans earlier... of course, wait until you know they are working properly. More info on them here (a bit down the page):
http://pages.prodigy.net/jforgione/MB_S500.html