$6K, and I thought I had a lot of $$$ in my long rod stroker :scared:
You didn't say anything about swapping out your radiator. If it has 200+K miles like the first motor it's due a retirement. Go with a 2 core Modine unit or better. I do not recommend the three core GDI. It works for some, but there are several that haven't seen any benefit because of one problem or another with the GDI (I’m one of them). Make sure the condenser isn’t plugged as well. It can really block airflow to the radiator and cause problems out on the highway.
You said you are running a Jet stage two. I think Jet says you need a 180* t-stat with it. Jet makes a good T-stat. What Rich said about the lower rad hose needing a spring inside and the cap change are very important. I don't recommend the 160* stat. I have seen some over-heating problems with it as the engine will not get to closed loop well at that low a temp. The 4.0 likes to run more than 160. It needs at least a 180*.
The other thing to remember, if the cooling system is having problems lower temp t-stats won't make the motor run cooler. The stat will just open earlier on the way to an overheating situation. It’s the same running without a t-stat; sometimes running without a t-stat will actually make an engine overheat easier.
Make sure you have bled the air out of the head. You can pull the temp sensor out of the head to aid in air removal. I also like to drill a small hole in the t-stat if it doesn’t already have an air bleed to aid in removing the trapped air.
High flow water pumps aren’t the answer if the radiator isn’t up to the task either. I have run a HESCO and FlowKooler in the past. I run a stock pump now and have no heat issues.
Hood vents are nice, but again not a fix if the rest of the cooling system isn’t up to the task. I don’t think they do a darn thing at low speeds without being able to switch on the aux fan manually.
Water wetter helps as does running a 50/50 or less antifreeze/water mix if your climate allows.
Another thing I would suggest for those with heat problems when at slow speeds (I know it’s not what your problem is, but I’m on a roll here
) is to run a relay and new power wire to the aux fan. On my ’91 the aux fan was powered by a tiny wire for the amps that the electric motor pulls. I ran a relay set up triggered by the small wire and powered by a bigger wire off the battery. It really sounds like it helped the fan’s RPMs and hopefully CFMs as well. The relay set up also makes running a manual aux fan switch easier.
Good Luck,
Bones :skull1: