Jeep Wrangler TJ Cooling System Overhaul FAQ

So it's OK to do this cooling system overhaul without replacing the radiator, water pump, and fan clutch? Or should I really do these as preventative measures?
208k on the odometer and I don't know if this has ever been done. No overheating/cooling issues that are visible.

Well if you do it without replacing the radiator, water pump, or fan clutch, that's not really overhauling the cooing system. In fact, if you don't replace those parts, what are you even replacing at all?

With 208k and no history of ever having done the cooling system, I think you'd be pretty foolish not to at least have this on your radar (and that includes all of it).
 
Well if you do it without replacing the radiator, water pump, or fan clutch, that's not really overhauling the cooing system. In fact, if you don't replace those parts, what are you even replacing at all?

With 208k and no history of ever having done the cooling system, I think you'd be pretty foolish not to at least have this on your radar (and that includes all of it).

I figured flushing the system is better than nothing. I have never done anything like this so I am hesitant ... but it's not my DD so what do I have to lose? I'll do everything! Thanks for the pep talk :D
 
I figured flushing the system is better than nothing. I have never done anything like this so I am hesitant ... but it's not my DD so what do I have to lose? I'll do everything! Thanks for the pep talk :D

Flushing the system is better than nothing, you're right.

I'm not saying you have to do everything now, but I'd at least start acquiring the parts and have it on your radar (y)
 
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With the mileage you have and not knowing the history, it would be wise to change it all out. Replacing items one at a time runs the risk pf other worn/weak components going out on you shortly after.

Something it did over almost a years time was buy all the parts I needed every now and then. It can be costly to buy all that stuff at once, especially if you buy MOPAR parts, so that spread the cost out over time (if you have that time and don't need to do it immediately). This past November I replaced everything in the cooling system except the heater core. It had been replaced a little under 2 years earlier when it started leaking.

I'd recommend using the factory constant tension hose clamps if you have them. I had issues with leaks using the worm style clamps. I went back to the factory clamps in November and have had none since.
 
I have learned so much from this site. Thank you to all who contribute.

This thread has me convinced to give this a go as it looks like Mopar radiators are only going to go up in price. I'm new to all this and just wanted to make sure that rockauto.com is an OK place to buy parts from as they have the radiator I need for my '97 4.0 auto transmission for $277 + $14 for shipping.

https://www.rockauto.com/en/parts/mopar,55037653AB,radiator,2172
Or do I just grab it for the $100 more on amazon so I know it's a safe buy?
 
I have learned so much from this site. Thank you to all who contribute.

This thread has me convinced to give this a go as it looks like Mopar radiators are only going to go up in price. I'm new to all this and just wanted to make sure that rockauto.com is an OK place to buy parts from as they have the radiator I need for my '97 w/ auto transmission for $277 + $14 for shipping.

https://www.rockauto.com/en/parts/mopar,55037653AB,radiator,2172
Or do I just grab it for the $100 more on amazon so I know it's a safe buy?

Rock Auto is legit and I have ordered from them for many different vehicles. Solid pricing, good reputation, slightly slower shipping sometimes.
 
Rock Auto is legit and I have ordered from them for many different vehicles. Solid pricing, good reputation, slightly slower shipping sometimes.
Agreed! Rock Auto rocks! That is where I got mine from, sitting on the shelf for when I need it. But as always shop around as there can be a lot of difference depending on what part you are looking for.
 
You're very welcome!

Yes, the OEM radiators were once a lot cheaper, but as Mopar stopped producing them, they've gone up in price significantly. At some point soon you'll never be able to get an OEM radiator again unfortunately.


Hey Chris, you bring up a good point: I think I might order / store a backup OEM radiator for future use on my '05 TJ, since I plan on keeping her for some time. Any other "hard to replace" OEM parts / components anyone can think of that might be good to have on hand for down the road? I imagine a list could be quite extensive, maybe just the big show-stopper parts. Thanks!
 
Hey Chris, you bring up a good point: I think I might order / store a backup OEM radiator for future use on my '05 TJ, since I plan on keeping her for some time. Any other "hard to replace" OEM parts / components anyone can think of that might be good to have on hand for down the road? I imagine a list could be quite extensive, maybe just the big show-stopper parts. Thanks!
OPDA* and Fuel pump
 
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Hey Chris, you bring up a good point: I think I might order / store a backup OEM radiator for future use on my '05 TJ, since I plan on keeping her for some time. Any other "hard to replace" OEM parts / components anyone can think of that might be good to have on hand for down the road? I imagine a list could be quite extensive, maybe just the big show-stopper parts. Thanks!
I've been considering starting a thread about hard to replace parts. Now I will.
 
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Hey Chris, you bring up a good point: I think I might order / store a backup OEM radiator for future use on my '05 TJ, since I plan on keeping her for some time. Any other "hard to replace" OEM parts / components anyone can think of that might be good to have on hand for down the road? I imagine a list could be quite extensive, maybe just the big show-stopper parts. Thanks!

All the electronic sensors, OPDA, fuel pump, radiator, water pump, and I think that's most of it.

Oh, and most importantly, a replacement PCM, which you can talk to @Wranglerfix about. Above anything else, the PCM is the most important.
 
Rock Auto is legit and I have ordered from them for many different vehicles. Solid pricing, good reputation, slightly slower shipping sometimes.

I did this today and figured I'd post the RockAuto order. If nothing else it'll show a snapshot in time for prices and list of part numbers that worked for a '97 4.0 Automatic with no AC. I had replaced the heater core and hoses a while back. Today was the rest of it with the following list. The only thing that seemed a little off was the bottom radiator hose needed a few inches cut off. The Hose Clamp Pliers wasn't very useful.

Thanks again for all of the great HowTo resources up here.

1602972290986.jpg
 
I did this today and figured I'd post the RockAuto order. If nothing else it'll show a snapshot in time for prices and list of part numbers that worked for a '97 4.0 Automatic with no AC. I had replaced the heater core and hoses a while back. Today was the rest of it with the following list. The only thing that seemed a little off was the bottom radiator hose needed a few inches cut off. The Hose Clamp Pliers wasn't very useful.

Thanks again for all of the great HowTo resources up here.

View attachment 196837
Besides that list what would you add for a 98 TJ with AC?, I'll try to add the ac on the next month, I live in Mexico so is very hard to get parts for a TJ, even the coolant, right now i did a flush on the coolant system but I'm planning to do at least two more and after that, change to the right coolant and change my coolant system or at least hoses thermostat and clamps. driving at the city i have no problems with the wrangler but when I'm driving at the highway for an hour at 65MPH or more it starts get hot about 210-220F. also it smeels like coolant whenever I open the hood so I'm a little worried about the cooling system, I know it has more than 20 years so I'm aware I'll have to change almost everything but I'm running out of money...

Greetings for Mexico!
 
Besides that list what would you add for a 98 TJ with AC?, I'll try to add the ac on the next month, I live in Mexico so is very hard to get parts for a TJ, even the coolant, right now i did a flush on the coolant system but I'm planning to do at least two more and after that, change to the right coolant and change my coolant system or at least hoses thermostat and clamps. driving at the city i have no problems with the wrangler but when I'm driving at the highway for an hour at 65MPH or more it starts get hot about 210-220F. also it smeels like coolant whenever I open the hood so I'm a little worried about the cooling system, I know it has more than 20 years so I'm aware I'll have to change almost everything but I'm running out of money...

Greetings for Mexico!
I’m pretty sure the only thing that would change with AC is a different belt. The presence of AC doesn’t really have anything to do with the cooling system.
As for the smell, you probably have a leak, and depending on how old you’d current radiator is, it’s probably that. I got my 97 back in 03 and it already had an aftermarket rad in it. Went through four auto part store rads before I finally decided to buy the mopar. The cheap ones rot out and leak so quickly.
 
6 Cylinder Models:

1997-1999 (4.0 liter 6 cylinder)

Waterpump: 68382489AA
Thermostat: 52028186AC
@Chris : I just checked We R Mopar and Summit Racing for the water pump and both are showing a mismatch (see below - I ran the VIN and double-checked both). Thinking about going with another brand although it gives me heartburn because water pump is not something i want going out 30 mins from a shop...

Also, Amazon doesn't seem to be carrying as many Stant products these days, i had to go to ebay and only a few of those thermostats were left from independent midwest dealers...

1614910412465.jpg

1614910464290.jpg
 
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I did this today and figured I'd post the RockAuto order. If nothing else it'll show a snapshot in time for prices and list of part numbers that worked for a '97 4.0 Automatic with no AC. I had replaced the heater core and hoses a while back. Today was the rest of it with the following list. The only thing that seemed a little off was the bottom radiator hose needed a few inches cut off. The Hose Clamp Pliers wasn't very useful.

Thanks again for all of the great HowTo resources up here.

View attachment 196837

And the water pump fits on your 97? I keep getting warning messages that 68382489AA MOPAR water pumps won't fit a 98 tj... Thanks for the help here...
 
I just did this overhaul yesterday. I ordered exactly the parts listed in the original post. I then read more of the later posts where it was said only use a Mopar fan clutch. I ordered the Hayden from the original post. Has that fan clutch been a problem for people? Also made the boo boo of using tap water. So today I ran five gallons of distilled water through system and then added back 2 3/4 gallons of Zerex G05. After water I kept draining and adding Zerex until it was good and yellow. Drove for a while and never hit 210 degrees which is where it stayed before the overhaul.
 
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Are the fittings on the Mopar 5503 7653AB barbed? The Jeep I'm working on has a replacement radiator and the transmission lines are attached to barbed fittings.
 
Quick Question for TJ Gurus and fellow Jeeples who have done the Cooling system overhaul: As this is being done on a 15-20+ yrs vehicle which will have a few rusted bolts. Did you encounter any broken bolts during this upgrade? If yes — which ones? If not — how did you overcome that?