Swapped the rad out about a week ago.
The old rad was leaking under pressure near the top hose and was allowing the coolant to boil at 100 degrees cos the system wasn't holding pressure. I had to add approx 2.5-3 litres of coolant per trip (if driving more than say 30mins), but i did avoid driving it obviously.
I was out wheeling at the beach when crack blew out on the rad (I had a suspicion there was already a crack somewhere) so that didn't help its cause. I left straight away and on the drive out towards the road and home I monitored the coolant temps and made sure that they didn't get over 100 degrees, if they did I'd pull over and let it cool, check the coolant level and keep driving again. That meant that I wouldn't need to add as much water in, as over 100 degrees and it would take forever to cool and it would start pumping water out the crack in the rad.
I bought this rad:
http://www.ebay.com.au/itm/Radiator-...item4aa7e7e193
They were good guys to deal with and I receive it within 3 days to Perth.
Also got a new thermostat and hoses from RockAuto. But didn't fit them cos 1. the thermostat didn't fit and 2. all in all the thermostat and hoses looked like such cheap quality junk compared to whats on my Jeep now.
There was nothing wrong with the current thermostat and hoses so just stayed with them and will use this new stuff from RockAuto as spares (not that the thermostat is any good to me, so will prob need to get another one)...
Used blue RTV to seal the thermostat in the housing (light bead all the way around the thermostat on each side), and high performance thread sealant on the trans lines going into the new rad. Also replaced the factory hose clamps with new screw style clamps.
Some pics:
Rad out with whole front end apart (yes its necessary to get to the rad!), pic looks daunting, but its quite logical and makes sense when you're doing it, and can be done in just under an hour:
New rad after all the hardware from the old one was swapped over (mounting brackets, trans lines, etc) as well as the secondary elec fan and shroud, all ready to be put into the Jeep:
Thermostat comparison:
New Rockauto one on the left:
How the old one fits into the housing (notice the little notch at bottom of the thermostat which the new one does not have...):
No way the new thermostat was going into the housing:
The box with part no. of the new thermostat (if you needed a thermostat for your WJ, don't get this one!):