Project XJ: Exhaust and Cooling System Overhaul

The cooling system in a Jeep Cherokee is far from efficient, and putting a winch on the front blocks some of your precious airflow as well. To fix this and keep our XJ running cooler we installed a Flex-a-lite aluminum radiator and triple electric fan combo. While we were at it we upgraded the rest of the cooling system as well. The exhaust system in our XJ was in dire need of replacement too, so we upgraded to a Magnaflow cat back system to replace the rusted out stock unit.
www.quadratec.c...
www.quadratec.c...

[@ClarkKulper]

My neighbor just gave me a 94 2wd cherokee a couple weeks ago. It runs fine but told me it overheats sometimes. So I went online and found quadratec them started ordering parts. This is my first jeep so it's good to know you guys gave these videos to help! 👍

[@SuperDagod1]

Since my son and I are keeping the XJ forever. This system looks beautiful, wow.

[@gordongreninger6109]

SuperDagod1 A very historical significant Jeep imo. One of the best wheeling Jeeps EVER. Id keep it and squirrel away a couple parts rigs.

[@cascalonginus4791]

Project XJ!!! What a BEAST💪🏼

[@Quadratec]

More great stuff coming soon!

[@smithredpilled581]

Your best to replace the viscous clutch fan plate with a new one first,this should really suck the air through the radiator , like when your XJ was new, If your having cooling problems this is definitely a replacement of the of the viscous clutch fan first ,before you replace or buy anything else.My XJ never overheats, even on hot days in heavy traffic or off road,and its only uses the stock factory cooling system!! If you have coolant loss it could be the frost plugs ,you will have to remove the engine to replace them all, don't forget the one at the rear of the engine! I replaced the old rusty steel frost plugs with new brass ones .

[@beersngearz781]

If I may make a suggestion, You should use some wiring conduit to clean up the wires

[@marcoantoniocasoascanio6905]

Nice video, nice job, I would like to have my Xj like your blue xj someday sir.

[@anthonyb8405]

Why wouldn't you solder those connections? This is a critical system being installed, im very surprised to see butt connectors being used.

[@gordongreninger6109]

Anthony B Why? I spent most of my youth butt splicing aircraft repairs on Carrier decks. We used a better quality conect and environmental heat shrink. The cheap shit works fine done right. Always check them post crimp tug the wires., done right 0 slip at crimp. They are butt UGLY. Buy the aviation grade $hit and never look back. They crimp with pins at 12-3-6-9 o clock.position on the barrel. You can not pull them apart without destroying the wire. Im more concerned with the sensor they mounted. Lose a belt at high rpm. Punch a hole thru your radiator in a light impact you shoulda, coulda drove away from. I got a sensor that sticks out like that on a gm lt1. Im constantly knocking the damn thing off during maintenance.

[@LtHawk77]

The only issue I had there is they used the basic cheap splices and electrical tape. They make really nice yet inexpensive butt splice with shrink connections to keep the water out and sealed. Thats my issue with it.

[@JeepITguy]

Sorry, disagree completely. I too have used crimp connections, but only when the connection wasn't critical. This is not an aircraft, there aren't the sort of vibrations in this vehicle that might be an issue for aircraft. I've had crimped conneections fail on vehicles due to the moist environment. Solder and heatshrink is the ONLY correct way to do it.

[@clashingview]

So i just received my flex-a-lite direct fit radiator and its not a direct fit. My problem is that my factory coolant lines interfere with drop in installation. They do not allow clearance on the passenger side. They are hitting one of the fans to prevent drop in. I can see if i force the radiator in, the coolant line will press against the fan shroud and cause the blade in that particular fan to hit the shroud. What can i do? I'm not experienced enough to bend or disconnect those lines.

[@coltons9522]

More XJ Videos please 👍

[@BadmunkyWRX]

Project XJ baby!!!!!!!!!!!! Love this rig guys! Keep it coming!

[@Quadratec]

Thanks! We have some more great stuff lined up!

[@BadmunkyWRX]

Sweet!!! This is my favorite project vehicle you have built so far!

[@inthemusic0075]

I hope this will fit my 88 xj

[@Steamfan85]

Would love to do this upgrade

[@weswood151]

MORE PROJECT XJ! Oh, and do you have a complete parts list for this install?

[@Quadratec]

+William Wood we are working on a page now that will show all the parts so far!

[@calid5933]

Love the Project XJ videos and your website has been invaluable as I order and build my own XJ. I bought my stock XJ last August with 156k miles. I have not had overheating issues at this point but I am headed to Moab this summer for exploring and medium crawling. (Fins N Things, Hell's Revenge.. How do I know what to upgrade as far as cooling systems go?

[@Quadratec]

Might not be a bad idea to replace your water pump, thermostat, and while you are there this tube is almost always rusted out www.quadratec.com/products/51212_1000.htm if you don't want to make the jump to an aluminum radiator just yet, remember if you turn on your defrost or a/c, the stock electric fan will kick on and help cool the engine. We have some more great stuff in store for this jeep, so make sure you stay tuned.

[@pablobeltran6724]

Where can I found a thermostat housing like that ???

[@dobbse.261]

You think adding that transmission cooler would destroy the transmission if the fluid was never changed with about 135k miles on it. Like we have all heard about how you change the fluid early miles, or you never change it.

[@zeyadalmamoori4477]

did it work tho >>???

[@beersngearz781]

Great video!!

[@rc9266]

Nice Job, but splices and tape are perfect I have never had a problem when Splice is crimped properly. I had a girl try to crimp them once but they kept pulling out. Girly hands should use solder to keep splices together.

[@rexraw5067]

how are Temps with this set up?

[@Quadratec]

So far so good! what's really nice about the variable speed controller you can set the fans to come on at any temp you would like, so we have it set so the temp stays right between 205-210.

[@scottvassar6728]

What battery terminal ends are those?

[@Quadratec]

They are the Quadratec Terminals: www.quadratec.com/products/17004_9002.htm?XJ_radiator_exhaust

[@scottvassar6728]

Quadratec awesome, I will be ordering

[@officialWWM]

That’s an expensive cooling system upgrade!

[@hidel308]

That Mopar water pump is garbage! Cure all of your XJ cooling problems with 80 bucks. The Flowkooler 1747 Water Pump is all you need. Keep the $400 you save for other mods.You’re welcome.

[@Quadratec]

When using a more efficient radiator like this one, the flowKooler won't allow the engine to ever get to the correct operating temp. On a stock radiator the flowkooler is a great option!