Having spent hours researching the net, and this site as well as other Cherokee sites I have determined that buying a new replacement radiator for our XJ's is a crap-shoot, roll of the dice, or a flip of the coin, and therefore almost a waste of time. "Almost" I say, but still edumocational in the sense of reducing your failure statistic by not buying the worst.
I have concluded that plastic tank models are a crap-shoot, in that there have been members here who have been very ticked off, and one showing a fist sized blow-out!!. Our local NAPA can only order a plastic tank model, (Modine, I think), replacement from hundreds of miles away, (as the dice rolls). Modine used to have a great reputation, but not what I would feel confident now for the XJ type they offer.
Others stand by their Griffin radiators.., but one stood there looking at his lemon leak anti-freeze fluid big time. I would've gone for the top of the line varieties, but again.., just where is quality control these days? There are a couple of others in the top tier, but don't come to mind right now, one costing around 6 or 8 hundred, but I have even read about one failure. Go figure.
A two core Champion gets a 50/50 vote, but for the price on all aluminum, (CAD cut, good looking welds), it was a better option for me to gamble with. My OEM 215k radiator rotted out in the past fall, (caught the issue at idle, shut it down), and ordered a priced right Champ., (relative, lol), from radiatorexpress.com for around $180, plus shipping. It has been through some rough service sub-zero use, and so far ok. The summer season will put it through some different expansion/contraction runs.., so I am waiting for the coin's flip to reveal it's answer.
If you get aluminum be sure to NOT use the green stuff, but use the orange stuff instead. In order to check the over-flow tank, the green is much easier to see than the orange, however.
I usually do a quick check of my oil, anti-freeze levels dead cold daily before start-up in order to insure proper operation on the adventure ahead, (lol). I figure getting a NAPA unit as a spare to carry in the box, secured to the roof rack should I go on an extended road/trail trip, (along with spare starter, battery, fuel pump, water pump, tire, etc.). As old as my XJ is, perhaps I should just tow another XJ behind it for all it's spares. :repair: