Jeep Cherokee XJ E-Fan Aluminum Radiator Conversion -

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Temp Switch -
Painless Performance 30111 Thermostatic Switch 185 on / 175 off
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[@tonydrummond3709]

When I installed mine, the fan motor on the right side of the radiator was re- clocked so the wiring was facing the battery so it would clear the bolts that use to hold the old clutch fan on. Ran all three fans on their own relay, fuse and switch. Only run the fan on the drivers side when a/c is on or in heavy traffic. Also running a Hayden 678 trans cooler after fluid goes through radiator to help trans stay at a safe temp.

[@HFG]

That's a good idea. I don't have a trans temp gauge on this yet so I just have to guess that the integrated cooler is working. Overall it seems to run and drive pretty well for a bunch of unknown parts on pallets. 👍🏼

[@danhambrick6331]

Yeah,that was real easy install.Plug n play....😂😂😂

[@HFG]

😂😂😂 a little more involved than I was originally planning lol. Still, not super terrible overall

[@briankinnear7461]

Thanks for sharing. The new rad looks great and seems to work as expected. Guess some driving will be the real proof. Be safe and stay well.

[@HFG]

Thanks 👍🏼 I've had a chance to drive it around and the temps are rock solid. Even in long, dead stopped traffic it cools great. The quality is good, too, for the cost.

[@GoonieLord]

All Cherokees have their issues but they will last forever with proper maintenance. A 4x4 that refuses to die and will carry on in any situation

[@HFG]

For sure!

[@user-gg8dm2mf1m]

I was a GM/ Chrysler service manager for several years. I watched 5 videos this morning, seeing if I could find a simple way to tuck away the a/c wires and lines without removing everything to install an a/c by-pass pulley . I've've watched several online how-to videos, I wonder how many actual technicians watch these videos for sport and entertainment. TRQ is the only group I've seen with their shit together and actually know what they are doing. Good luck, DIY'ers trying to get your repairs and projects correct watching these videos.

[@HFG]

I'm a hobbyist working on my own stuff. Most people who watch my channel are DIY'ers getting it done with what they have. If you're a pro, looking for pro content... sorry to disappoint.

[@AbsoluteAggr]

This is amazing video. The details you throw out over every hiccup with the aftermarket rad/fan setup are great. I clicked the link, was amazed at price, and then watched the rest of the video lol. Still doable though!

[@HFG]

Right on 👍🏼 I don't know what the prices are now but it's a good radiator. Definitely not a drop in replacement but worth the effort in the long run

[@MajorWeakness]

I've got 2 2000 model XJs. I've got to have AC where I live lol. I'll check out your other videos. Great video!

[@HFG]

Nice! Thanks 👍🏼 It would be nice to have AC here but Michigan doesn't have a very long summer so I guess it works out.

[@tonydrummond3709]

Everything in this video works for a xj with a/c.

[@issaalmasuodi4111]

Thanks for sharing this video, i do same work in my xj 98 . I live in hot weather country and all xj suffering heat issues

[@HFG]

I wish I lived in hot weather country!! I've seen a lot of rusty buildup inside a ton of 4.0 blocks. I always recommend that people with overheating problems find a good solution for flushing the block super well then work on the rest. I think these trucks are just abused over time. A lot of government agencies used these trucks is hot states without issues when they were new. I sure do love these XJ's 👍🏼

[@claycoates5056]

there is an easier way yes a new Radiator then add a second fan and a controller for less then $250 in 2022 i have made this conversion on a few XJs and this worked wonders also install a oil cooler for the Trans. WOW that will really helps the transmission in there things works well but it dose get HOT interesting video thank you

[@HFG]

I'm glad you liked it. This conversation isn't the ideal scenario for everyone, but it was a fun addition to the XJ 👊🏼👊🏼 Thanks for watching.

[@deadcell85]

Love it. With all that wiring it may be worth having 2 relays and 2 temp switches. Relay 1 a single fan at 180 degrees and 2 fans on 200/205 switch. It would cut down on cycling, noise and save you amperage. Thanks for the super helpful vid

[@HFG]

Yeah, that would be a better way. I've been planning on adding relays for each fan but I haven't had the time.

[@officialWWM]

I just wired mine into the wiring that goes to the factory electric fan. Works great!

[@HFG]

I didn't want to risk pulling too many amps through that wiring. Especially since there are now 3 fans instead of one.

[@officialWWM]

@@HFG yeah, that’s fair enough. I am running 2 fans off it and haven’t had any issues but I’m not as clever as you, so wiring up that setup you have isn’t an option for me 😂

[@HFG]

@@officialWWM Ahh, you could do it :) Have faith! I'm glad you liked the video.

[@RawTravis2112]

@@officialWWM how is that working out? I was thinking of doing the Same. To just wire in the 2 outside fans. I have a 160 amp alternator out of a Durango.

[@officialWWM]

@@RawTravis2112 it’s working great! I wired a second fan to the first one then wired both of them to my second battery with a switch. They still turn off and on automatically but I can also turn them on at will. Very handy when crawling off-road on a hot day!

[@franciscomurillo8469]

Great video! I just finished doing this for my 99 XJ I feel like it’s to much work just to make it fit, there was a lot of cutting for me in my radiator support bracket. I like that clean finish oem look when I work on my cars. I would save a little more money and buy a better brand.

[@HFG]

This one definitely requires a little modification 👍🏼👍🏼

[@tonydrummond3709]

Also Amazon sales the parts to make plugs that will plug into the pigtails on the fans, and heavy-duty relays with 12ga wires, and inline fuse holders with 12ga wire.

[@HFG]

I'll have to grab some for next time. I talked with AlloyWorks and they said they were going to offer a heavy duty wiring upgrade kit for the multi-fan units.

[@cuevaslegrand]

@@HFG did they say when? I’m planning on buying this radiator/fan combo.

[@HFG]

@@cuevaslegrand No. I checked their website about a month ago and didn't see any upgrades wiring kits. I would suggest just using the relay itself and buying a heavier gauge socket/pigtail and fuse holer online. They're pretty cheap on Amazon. The radiator is really nice, so just don't use the included wiring stuff.

[@henryescat1104]

Cut a wood triangle and attach it to the bottom of your tripod.. Then put a weight or sandbag on the plywood triangle to keep that tripod steady and upright..

[@HFG]

Good idea. This tripod is too crappy to even hold any weight. I'll have to just get a new, better one.

[@henryescat1104]

@@HFG There all tippy when youR tripY over the cord.

[@HFG]

@@henryescat1104 😂😂 So true

[@brad3378]

$215 with fans is VERY reasonable! Nice find.

[@RodneyMcDonald-cx7yh]

I have told them about that problem with the neck also gave them the heads up

[@HFG]

Maybe they'll change it some day 🤷🏽‍♂️

[@RodneyMcDonald-cx7yh]

@HFG yes won't be to long

[@HFG]

That's good. It's a great radiator. It was a little work to install but well worth it. The thing holds rock solid temps even in the hottest weather.

[@TheBackpackingSailor]

i trust any mechanic dude who looks like this guy

[@HFG]

👊🏼👊🏼 I appreciate it!

[@TurlosGarage]

That XJ has all the Torx

[@HFG]

😄😄 It sure does!

[@claycoates5056]

And they work Well

[@HFG]

@@claycoates5056 I'm not a huge fan of the two E-Torx bolts on top of the bell housing though 😂😂

[@gregj.gotham4402]

Stewart’s electric Syracuse Ny has them

[@HFG]

👍🏼👍🏼

[@jasonbarrett3399]

I plan to do this install....Couldn't the lower tie bar between the frame rails be drilled out forward towards the bumper so that the radiator could be moved forward without tipping from the top?

[@HFG]

Maybe. It was way easier to modify the header than do anything where the radiator sits. Give it a shot. 👍🏼

[@denzellsmith5963]

What size tap and drill did you use to make the new hole in the thermostat housing?

[@HFG]

That depends on which sensor you buy. Some of them are small than others, but I don't remember specifically on this one. Sorry. Whichever you buy, just make sure it's a NPT

[@andreolivier2994]

Have you noticed a big change in gas mileage /power since your engine doesn't have to drive that stock metal fan anymore?

[@HFG]

Nothing noticable. If I had to guess I'd say it might be a wash between drag from the mechanical fan vs drag from the alternator to power the fans, but I haven't noticed any difference to be honest. It cools a lot better though.

[@projectbumblejeep4190]

The square drive plug in the side of the block for the "sensor" looks to be 3/8" so a ratchet or extension should work to remove that plug. Hind sight, right? God bless, stay well.

[@HFG]

For sure. Getting under the header looked kind of tricky, but probably still easier than what I did :)

[@RABERTRON]

Its not. I think its 5 1/16

[@RABERTRON]

What is the best Temp T-Stat to run now since I have the new Fancy Radiator with fans ?

[@HFG]

I think I bought a 185° and it's been good. My temp gauge in the truck reads high but my truck has always been nice and cool 👍🏼

[@dalebrooks4444]

I'm doing the same swap but I need to remove the studs from the clutch fan pulley to replace them with shorter bolts. Any advice on how to remove those studs would be greatly appreciated

[@HFG]

I had the same issue. You can just do what I did in the video and cut them. Or you can jam nut the stud, lock it with a pry bar and try to back the stud out without breaking it.

[@dalebrooks4444]

@@HFG thank you I appreciate the advice

[@HFG]

👍🏼👍🏼 No problem. I hope I was clear enough in the video. Let me know how I can improve.

[@RABERTRON]

Mine is still getting very hot . I replaced the messed up Head Gasket . I have tried 3 Relays ,none of them will kick the Fans on . I think that the sensor that came with the Radiator is shot. Do you remember the Part Number for a new Sensor???? The 30Amp Fuse blew too, it is all melted inside and the fuse holder for it is a lil Burned up inside. I will need a new one .

[@RABERTRON]

I have a Switch hooked up to turn the fans on and off. I might try driving it and turn the fans on when stopped I live in Baltimore City so do a lot of stop and go traffic . I am still wondering about using a lower tem T-STAT because of all of the Stop and go Traffic I drive in.Any input let me know .

[@HFG]

Try a lower thermostat, flush the block and heater core with the radiator disconnected so it doesn't get flooded with junk. You might even have a bad water pump. Sometimes the impeller will disintegrate. As far as sensors go, I don't know what the part number is. I just bought whichever one the parts store had on hand for the Jeep.

[@shaggyduder]

Most parts from 96 and prior are Omix, and they don't fit 97-01, are you sure that radiator was for an OMIX Jeep? BTW, the 4.0 wants to run at 210°, placing a lower temp stat. Will make it run cooler, but you'll have proformance issuses.

[@HFG]

No idea. Aftermarket stuff is hit or miss with fitment most of the time. I'll deal with the potential performance issues, although I haven't had any, to keep it running cooler. Especially considering how prone they are to overheating.

[@anarchistgreg4689]

Such a headache to upgrade!!! Just a new stock radiator is all you needed

[@HFG]

Probably. This thing cools like a beast though.

[@memo27bmx]

Have any part number for the shallow temperature switch? Cant find anything useful

[@HFG]

Check Amazon Painless Performance 30111 Thermostatic Switch with Adapter, 185 On/175 Off I think that's the one

[@edwardl.990]

I’m experiencing a leak on my 2001 xj , by the radiator cap and wondering what the best solution is.

[@HFG]

If it's not leaking from the cap then you might have a crack at the neck. Buying a new radiator is probably about the same price as getting yours fixed but you might want to ask a radiator shop. 👍🏼

[@chrisgrantham2341]

hopefully you tightened the overflow hose there first before buying a radiator

[@timmyrunion4345]

What did you do for the transmission cooling line it doesnt fit on new radiator

[@HFG]

It fits the new radiator fine. It's connected right now.

[@michaelwilkerson6722]

Great video! I’m about swap my 96 Grand Cherokee over after spending 400 bucks replacing radiator, super duty clutch and a larger fan which made no difference. I like your results and will do the same.. thanks again!

[@HFG]

Glad it was helpful. One thing that I would recommend that I should have done is put each fan on it's own relay. I'm going to be changing mine pretty soon

[@michaelwilkerson6722]

@@HFG brilliant idea sir! Btw… the site you recommended has my fan/radi setup and luckily it has one gigantic fan 🤠. Thanks again

[@HFG]

@@michaelwilkerson6722 good to hear. You're welcome 👍🏼

[@troymcdonald6750]

Listing for radiator shows for 91 and up. I have a 87. Would still work?

[@HFG]

I think your radiator is a little different than this one but if the size is close to the same then you could probably make it fit with some modifications. Measure your current radiator, height, width and length and compare it to one of these. Also how it mounts. I checked Alloyworks website for you and it doesn't list your year, but I guess it depends on if you want a stock, drop in replacement or if you don't mind a little customisation. 👍🏼👍🏼

[@RABERTRON]

For some reason mine might not be coming on .If I run a jumper wire from the switch to the Battery Neg ,it will come on ,but not turn off until I remove the jump wire from the Neg Batt . Also my OEM temp gauge stopped working and my radiator hoses are very hard .What is going ON??????

[@RABERTRON]

My OEM TEMP Gauge needle is in the 4 Oclock Position

[@HFG]

Sounds like you have a bad ground on the truck, or the switch isn't working. You can trigger the switch outside of the truck by using something that gets the switch above the "on" temp. Like a lighter or something. Just turn the ignition to the on position so the fans will kick on. Otherwise I'd say something is wired wrong, the switch is bad, or you have a bad ground somewhere

[@Velster]

Are the fans still working to this day?

[@HFG]

Yeah. I drove it today. They still work fine.

[@curtisdoss2469]

What I want to know is, how well these radiators last. I'm looking to buy one for a 78 Ranchero. I want to make sure it will last.

[@HFG]

Seems to be made pretty well. I've seen a whole lot worse, so I'm guessing that it'll be fine. Time will tell though. 👍🏼

[@curtisdoss2469]

@@HFG thanks for the info!

[@HFG]

@@curtisdoss2469 I haven't had it long enough to really give you the super long term answer, but it's been rock solid even in 98° weather and idling for long periods.

[@sponcastpodcast]

@HFG Hey brotha, I hope all is well. I know it's only been a month, but I wanted to know if you had enough experience with this that you think is worth the swap? Appreciate your time. Thank you

[@HFG]

@@sponcastpodcast Hey hey. That video is 5 months old, so I've had quite a bit of time with the radiator now. It's definitely worth the swap. Once the thermostat opens, that temp is exactly where it stays. I've had multiple 90+ degree days with the jeep idling for long periods of time and driving around. It's been great! In retrospect, I'd change the wiring more and add a relay for each individual fan instead of just one for all three.

[@brainshowers3925]

You did wayyyy more work than you had to 😂

[@HFG]

Probably, but it works great.

[@OysterPir8]

Wait. It has a transmission cooler incorporated??!!

[@HFG]

Yeah.

[@hectorhuerta6436]

Would this fit my 1991 jeep Cherokee 4.0 inline 6

[@HFG]

Better check their website for the correct radiator. It might work with modification.

[@thehatefull1761]

You can most definitely make it fit if you have any experience in fabricating or if you're just very tenacious and refuse to give up you can make anything work

[@ethanrobbins3387]

Just got mine installed a couple weeks ago, now that you’ve had yours a while how is it long term?

[@HFG]

It's been great. I switched to using a separate relay for each fan, but the cooling has been rock solid with no issues at all. 👍🏼

[@ethanrobbins3387]

@@HFG what issues were you having with a single relay running all 3 fans?

[@HFG]

@ethanrobbins3387 nothing really, but it's a lot of amperage for one relay. It's safer to use one for each fan. Then if something happens there's redundancy.

[@ethanrobbins3387]

@@HFG I see, I appreciate the response man, your video definitely helped along the way, very detailed 👍🏼 I dig your Cherokee

[@HFG]

Thanks! I really appreciate it. I'm always happy to help when I can. If you haven't seen the early videos of what my Jeep started out like, you should check it out. It was a mess to say the least. I'm glad the video helped 👍🏼

[@christophernewport698]

I have a 99 Xj I just bought one of these for it do you have to take off the manual fan for the engine to make it fit ?

[@HFG]

I did. Maybe it'll fit if you removed some of the electric fans... not sure. In the video I explain what to do with the mechanical fan.

[@christophernewport698]

Ok thanks I was just worried that removing the fan that it would have trouble keeping it cool enough

[@HFG]

@@christophernewport698 I haven't had any issues. It hits 185, which is thermostat temp, and stays there. Even on 90° days it's rock solid for me.

[@christophernewport698]

Great I’ll try it and let you know how it goes

[@HFG]

@@christophernewport698 Sounds good. There are some things you'll need to modify, or at least I did, so check out all of the video to see what to do.

[@edwardl.990]

How much did you pay for the aluminum radiator??

[@HFG]

At the time I think they were going for about $200 but I don't know what the price is now. I'm pretty sure they're available on Amazon and a few other places 👍🏼

[@madmacks]

At 28:22 your video shows the Jeep with the air intake on the passenger side?!? It looks like the video has been flipped left to right. Pray tell, why? Or am I missing something?

[@madmacks]

Ah, forward facing camera vs rear facing camera? Or you have a magic Cherokee…

[@HFG]

@@madmacks You got it. I try my best to catch those and reverse it. Using a phone has quite a few disadvantages. Sorry about that.

[@madmacks]

@@HFG It’s all good…your vid is well worth watching. Thank you. I just did an engine swap on a ‘91 Cherokee Laredo and I bought the same radiator upgrade you installed. I put in a 160° thermostat and bought a separate radiator hose in-line sensor (off at 170°, on at 185°) that I’ll use instead of drilling the housing and using the switch they provide. But I am concerned about the clearance issue as I have and use AC so I need the cooler installed. And I’m also concerned that the auto tranny lines may not match up. Guess I’ll find out just how easy this thing is to install…

[@HFG]

@@madmacks mines an auto and the lines were on the money with no modification. As for the condenser... I think it'll work if I remember correctly. Let me know how it goes for you.

[@madmacks]

I will…looks like a nicely made radiator, but the Cherokee is so cramped in the engine bay they should spend more on getting the fan shroud thinner I’d think.

[@rayvarnson8976]

Use button head bolts to replace fan bolts.

[@HFG]

I don't remember what I used. I thought it was all stuff that was in the kit, no?

[@ivanbrannon9900]

What location exactly did you use for 12v source

[@HFG]

Fans are battery source. Relay is key on power with an override switch in case I want them on or the temp switch fails. I thought I had that part in the video.

[@ivanbrannon9900]

Sorry what fuse location did you use inside cabin

[@HFG]

@@ivanbrannon9900 there was an unused keyed power source in the fuse block. I don't remember which location but it was empty and unlabeled.

[@ivanbrannon9900]

Awesome thank you and also very helpful video

[@HFG]

@@ivanbrannon9900 👊🏼👊🏼

[@RABERTRON]

What is the Part # for that Switch??? I need to get one to finish my Install.

[@HFG]

The temp switch on the thermostat housing?

[@RABERTRON]

@@HFG Yes the one that you bought t add t the T stat.

[@HFG]

@@RABERTRON check the video description. The switch is listed there. 👍🏼

[@RABERTRON]

I dont remember seeing or hearing about the Part #@@HFG

[@HFG]

@@RABERTRON I copied this from the description: Temp Switch - Painless Performance 30111 Thermostatic Switch 185 on / 175 off

[@deadspeed6679]

Yea I’ll skip

[@HFG]

It's not for everyone

[@deadspeed6679]

Just wish they had taken more time and rolled out a more stream line product. jeep xj radiators are either really expensive or cheap and not worth the money this could have been a good one if they had taken time to plan it out more good video thought