I have a 1996 classic 4.0L Automatic on 33s. I Recently installed a new bumper and winch before the winch there was no cooling problems. Now any driving of 55+ for extended time puts the heat to the third notch and on highways for 20 min today it tipped the red. But as soon as I slow down it sits just above 210 again. I am choosing to upgrade the cooling system since it's still the original radiator I will be putting the ZJ fan clutch in as well as good vents. As far as a radiator should I stick with a OEM replacement and of not then what should I upgrade too?

 

I used the Champion 2 row and its been good no problem in the heat I stay lower the 210 at all speeds .

 

How long have you had and any problems getting it in?

 

Do you have intact fan shrouds?

 

Excellent question. Why so many people seem to thing the shroud is optional is a mystery to me.

 

Mostly, the top of my mechanical fan shroud is broken but Jerry rigged in place

 

Fan clutch:
I went with NAPA 272310...which is a 96 cherokee 2.5l fan clutch....much heavier duty than the stock one (not sure if it is the same as the ZJ you mention).
Pay attention to the clearance....too much thicker and it will hit the radiator

Radiator:
Make sure it is clean, and there isn't a bunch of mud & gunk between the cooling fins....same goes for between the radiator and the A/C condenser.....leaves & mud have a habit of collecting there.
Make sure you have a full fan shroud, it makes a big difference.
One of these would work well...
https://www.rockauto.com/en/moreinfo...80314&jsn=2183

https://www.rockauto.com/en/moreinfo...80314&jsn=2184

Aluminum versions seem to be hit or miss from reviews I've read. I've stayed with the factory replacement style, some have had good success with the aluminum ones, some not so much.

You may also want to look into putting a switch in to let you turn on the electric fan sooner....(here's a good writeup on it https://www.naxja.org/forum/showthread.php?t=1025399 )

 

The stock 4cyl fan clutch is the "upgrade". The 4cyl engine didn't have the electric aux fan so it depends fully on it's mechanical fan which is why it has more "lockup" than a 4.0L fan clutch. Hayden P/N 2737. They make a lot of noise and expect a 1ish mpg drop in fuel mileage, I keep one on my parts shelf but run an actual MOPAR OEM Fan clutch that I scrounged up. This won't effect the OP's highway overheating problem as airflow at highway speeds is more than the fans can flow anyway, he most likely has a water flow issue. Either clogged up radiator tubes or a bad water pump blade or stoppage somewhere else in the system.

OP just pick up a Spectrum radiator if you are replacing the radiator and call it good. As long as everything is working properly it's more than enough.

 

How much is the winch covering the front of the radiator? Do you have any pics? If the radiator was the problem it would over heat while idling.

 

Yep...2737 is the one I got.....wasn't sure if it was the same clutch or not.

 

So here is the deal, you have an air flow problem caused by having a winch in the way. If you keep it there, you need to either upgrade the fans or the radiator. But yes, intact shrouds are a must for proper air flow

 

The Champion radiator fit in with no problems , I did not have to modify anything .

 

I would not spend a dime on a radiator until you have replaced the fan shroud. It's an obvious problem and may be the solution.


I will never understand why so many people think the fan shroud is optional. Hello? Its purpose is to create the correct air flow. You have an air flow problem. Maybe there is a connection.

 

I never really thought about it until it was pointed out and I have ordered a replacement fan shroud

 

I have the Champion 2 row with the triple fan,also run a 180tstat,ran way hotter faster with the 195.Cant keep this engine cool to save my life. About to go back to stock radiator and stock fans with the proper shroud,no problems cooling when it was all stock equipment.