When I rev it I can hear the wind woosh and it sounds like a semi truck. Tried to spin the fan manually and it will not free spin at all. I'm calling it dead and figure it's time for my first upgrade.
I'd just buy a new fan clutch. They really don't rob that much power and the cost vs gain ratio is terrible.
Put the money (and headaches) you save into parts that are more beneficial.
The alt upgrade, fan, wiring and controller add up and you definitely don't get your $300-$500 worth of hp from it.
Ignore my comment if when you said "upgrade" you mean upgraded fan clutch (not sure if the HD unit is still available).
Between half price day at the parts yard and Craigslist I was able to upgrade the alternator to a 3G unit and install a electric fan with controller for about $80. For now it fits the bill and keeps the car cool/charged, and quieted the thing down quite a bit.
I need to take a few hours and detail the engine bay and paint the intake plate.