In my experience, in the heat of the Phoenix desert, I have not found a bad radiator. All the factory ones an all 4 TJ’s/LJs popped EVERY SINGLE ONE, but they always cooled, they just weeped coolant on top. Never had an overheating issue on any Jeep, full AC, 120+ degree days, blah blah blah.
When I replaced the OEM Units
I always use a 195 degree thermostat
I always swap the fan clutch with a Hayden heavy duty
But when I was new with my first 98 TJ 5 speed. I put a 3 or 4 row copper/brass CSF. It worked, but I would see the needle dance around 210 (yes it would sway a bit). Wheeled the crap out of this thing in AZ. Fun fact, I went muddying for hours in this rig, needle was dancing more than usual, when I deep cleaned off all the mud when I got home, the radiator was just packed with mud. Killed an air filter and a MAP sensor but still didn’t overheat …
Next Jeep I got “smarter” and put a 4 core aluminum champion radiator in my LJ Ruby with an automatic. This radiator was a beast, but would run a little above 210 with stock fan clutch, heavy duty was able to overcome the resistance of the 4 cores, never overheated. I never really wheeled this one.
Next Jeep was a LJ 6 speed, I listened to the Mopar hype and bought the stock replacement. Was perfectly fine but at this point I was in San Diego, wheeling in the desert, but not as much as I did my first love, I mean first Jeep.
Next Jeep I bought to show my San Diegan wife the beauty of the AZ desert, moved back and had to make it appealing. used Mopar. Perfectly fine, never an overheating issue.
When I pick up my 5th, LJ here shortly, I’ll be putting a Mopar unless someone like Dewitt’s starts making Jeep radiators.
MORAL OF THE STORY: they all work, make sure your junk is flushed, fresh coolant, 50/50 coolant mixture (I always use G05 and distilled), 195 thermostat (I have gotten bad ones twice), fresh fan clutch (heavy duty is extra loud until it releases). In terms of absolute limits, limits beyond my experience, avoid the fancy foo foo, the 4 core copper CSF and 4 core aluminum champion seemed closer to the limit of their performance envelope, I feel the stock MOPAR had more overhead… again, overhead I never needed in the desert. If only the bastards wouldn’t crack.
In other cars/rigs if you pounding axle snapping power high centered in your favorite rock garden, take a few seconds to be kind to your rig and run your truck at higher rpm at idle to let the fan move some heat, then proceed to romp around. This also works to get your AC to chill a bit more if your stationary for a while.
I would love a real American made, full welded aluminum radiator, pressed end tanks, same core design as factory, perhaps extend the core from 1” to 1.25” tubes. Or dual 1”. Any more then that and I believe the cooling stack becomes too restrictive. But all this would do is look pretty and give me the warm and fuzzies that this might last longer than the mopar 10 year life, and possible keep me cool when the tree hugger prove they’re right and Phoenix goes up to 135 degrees in the summer.