They are definitly pulling enough air. And it wouldint be the fans because it overheats on the free way too.

mine had a running warm issue in stalled new fan clutch and it stopped when running highway so fans canstill be cause ....

Am I missing something here? If the IR temp verified the mechanical temp, does this not mean "case closed" regarding overheating? Sounds like the problem is a whacked dash gauge, not overheating, no?

Does the mechanical gauge indicate +/-205 both slow and hi speed driving?

Yep. Went crawling yesterday kept getting to 240. With heater on max. So i kept having to pull over and raise the hood and let her idle to cool her down. And on the freeway she gets up too 240 too, so airflow is not the issue. And those temps where with my mechanical guage in the heater hose right by the thermostat housing.

I had a new fan clutch before i put the mech fans on there and it was still overheating.

But if you truly think that my elec fans are not pulling enough air i can always put it back on. It is just sitting downstairs with a brand new clutch. I have both shrouds and stock mech fan too.

I can see the efans being an issue at slow speeds/crawling but, at road/hi-way speeds shouldn't need any fans and efans should be OFF for max air flow thru the rad at hi-way speeds. If it overheats at hi-way speeds, I'd suspect the rad/tire/ambient temp combo and/or airflow restriction thru the grille and to the rad.

The a/c condensor is brand new so fins are all nice and clean, so i just dont think airflow is the problem.

putting back on stock fans would eliminate air as a issue id try it did you read the link on flow restrictor i posted....?http://www.go.jeep-xj.info/HowtoRadiatorRestrictor.htm

Ok, there's no air flow restriction. Then my guess is, the rad is insufficient with regard to the extra load of 35" tires and present ambient air temps.

As a test/experiment, have u tried running without a t-stat under the same operating conditions/ambient temp/driving speeds?

I have not. But i will do that tomorrow most definitely! Thanks!!

whats the highest the aftermarket mechanical gauge gets ?

It has gotten to 240. A lot. Then I pull over and let her cool down.

I think two things need to be changed.
Water pump and Rad cap, BOTH from the Jeep Dealer.
those two things make a huge difference, if the quality is off then the performance will be too.

Well, i just did another rad flush, and i ran w/o a thermostat for a couple days. It still overheated, with out the thermostat. But i just put a new one in tonight and filled her up, and went for a drive and she dididint get above 205, so i guess we will see tomorrow if she is magically fixed. Thanks everyone!