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  #13  
Old 07-09-2013, 05:58 AM
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Re: ANOTHER overheating WJ

PROBLEM SOLVED!

Temperature Control Sensor caused a bunch of anguish and frustration. $30 part.
Once the Sensor was replaced, it took just one Radiator Fan Relay to correct the staying-on-all-the-time problem. (Instead if 8 in 2 weeks time)

Thank you to EVERYONE who provided support and ideas! You were ALL a great help!
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  #14  
Old 07-09-2013, 11:01 AM
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Re: ANOTHER overheating WJ

I can imagine that a faulty coolant temp sensor could cause the fan to run all the time and maybe fry the fan relay due overheating. Just wonder what that could have to do with the bursting radiator. Did you change the radiator cap as well?
Still funny also that the temperature indication was indicating normal.
But i hope that you have solved it now.
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  #15  
Old 07-09-2013, 01:24 PM
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Re: ANOTHER overheating WJ

Well, since I'm no expert, I am pretty good at guess-timating. So this is my educated guess...

After speaking with you guys, and getting input on this frustrating situation I was in, I followed a few steps and came up with the only thing I can possibly think might have happened.

Someone stated in checking for water pump failure, open the cap and let it run until it gets hot and the coolant starts to circulate. This will tell you that the pump is doing it's job.
After doing so, I decided to un-plug the Temp Control Sensor. Which I was also told would make the jeep turn on the fan. Since the relay I had kept the fan on all the time, I swapped it with one that wouldn't to see if it would still kick on.
Approximately 30 seconds after unplugging the temp sensor, the RPM's kicked up and the open radiator erupted coolant everywhere.

I figured that since the Temp control sensor tells the computer when to turn on the fans and do what it does to keep the engine running cool. That it was apparently failing, not at start up, but during road use, causing the radiators to build up pressure they couldn't hold.
I bought the new cap with release valve which seemed to help, but not sure if there is anything happening there. It still got hot, but I shut it down before I ended up buying a FIFTH radiator. However, the relay for the fan had a better response to the new Temp Control Sensor than it did for the old one. I never bought a new fan relay, I re-used one of the 8 I had and when turning on the AC it came right on, and turned off when I shut the Jeep off. The boiling over of the overflow reservoir hasn't happened at all and the loss of coolant has subsided, since the temp sensor was replaced.

As odd as it may sound, and trust me, it's ALL Greek to me, this is the only guess I can come up with as to how I managed to fix it. With ideas from you guys and a really good guess on my part. A $30 Sensor, if it weren't for warranties, might have cost me over $500 in radiators and give or take a head gasket or new replacement engine! Amazing! ...not to mention the mental anguish that went along with it all!
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  #16  
Old 07-09-2013, 02:22 PM
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Re: ANOTHER overheating WJ

The only part in the system which controls the pressure in the cooling system, is the radiator cap. It should release the coolant towards the overflow reservoir when a pressure of around 18 PSI is reached and should stay at that pressure. This higher pressure increases the boiling point of the coolant.
But the important thing is that it is working again.
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  #17  
Old 07-09-2013, 04:19 PM
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Re: ANOTHER overheating WJ

Makes sense. So in reality, I just had a cap the was holding in pressure rather than releasing it. An even cheaper fix at $6.50. Ah well, at least the fan, radiator, thermostat, temp control sensor, lower radiator hose and radiator cap are all replaced. Slimming down my chances of failure in those items.

Thanks again, because without the information you guys provided, I might not have been able to get through this. It was literally driving me crazy! You guys and this site are awesome!
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  #18  
Old 07-18-2013, 06:40 PM
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Re: ANOTHER overheating WJ

Alright, so I found out today I have 2 pinholes in the top driver's side of the radiator about 3" from the filler neck. This is the same location as all the other radiators have been breaking from. Going on radiator number 6 in a month and a half's time. It ISN'T overheating anymore, but it is creating a problem for me. Any ideas? They are Autozone "Spectra" radiators.
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  #19  
Old 07-18-2013, 08:17 PM
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Re: ANOTHER overheating WJ

again?
They are in the plastic tank? No crack and just holes? I can understand how a crack will form in the plastic tank due to overstressing, but a pinhole?
Did you check the hose from the radiator neck to the overflow reservoir if its unobstructed? Could you provide a picture of the pinholes? It would be interresting to see what the pressure in the cooling system is during normal operation.
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  #20  
Old 07-18-2013, 10:43 PM
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Re: ANOTHER overheating WJ

Sorry. No pics available...Radiator already swapped out, installing in the morning. Hose is not obstructed. Checked it out.

It was literally 2 pin holes pissing a very thin stream at the back of the grille and driver's head light.
Spoke with Autozone clerks, and one immediately asked me if the tank keeps cracking. I was like, "WHAT?!?!" So apparently I'm not the only one to experience this.
I told them I've had it with replacing radiators, they all crack in the same spot, this one being the only one to get pin holes. Also told them I wanted out of the warranty circle I'm in, and was told if it happens to this one, bring it back, they'll refund my money and I'm out of the warranty trap I'm in. I'm looking to try another brand other than "Spectra", and it's the only brand Autozone sells. I was told of the possibility of cracks due to body flex and vibrations...I doubt its the problem.
I also bought a 16 PSI radiator cap over the 18 PSI I just bought for it. So hopefully that alleviates some of the pressure and stress on the radiator.
Again, the list of repairs:
-Water pump
-Heater core
-Thermostat
-Temperature Control Sensor
-Radiator (6 times)
-Radiator Cap 18 P.S.I.
-Radiator Cap 16 P.S.I.

The overheating has stopped, but now there seems to be a pressure issue.
What is going on???!!! If I had the money, I'd drop in a Trophy Truck cooling system! Indestructible!
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  #21  
Old 07-18-2013, 11:13 PM
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Re: ANOTHER overheating WJ

I have a Spectra Premium radiator since 1 1/2 year and no problems.
Did you see any stress marks on this last radiator which had the pinholes? It looks almost if its indeed suffering from externally imposed forces, but still impossible to understand how it could create holes this time.
Does the 4.0 radiator have the transmission cooler in the right hand tank, as with the 4.7, or does it sit in the left hand tank, where the cracks and pinholes appeared?
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  #22  
Old 07-19-2013, 07:49 AM
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Re: ANOTHER overheating WJ

Trans cooler is on the drivers side, same side as pin holes. Looking to alleviate the trans temp by adding a trans cooler in the near future. Think it's the transmission? Heating up the left side of the radiator enough to crack it open or cause the pinholes? Guy at parts store was surprised mine didn't come with one from the factory.
There weren't any signs of a weak spot on any of the radiators. No white discoloring of the plastic or damage to the boxes. They all seem legitimately in good working order. Any questionable markings might have made me questionable and not install it. But there was nothing.
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  #23  
Old 07-19-2013, 10:38 AM
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Re: ANOTHER overheating WJ

Just trying to put all posibilities on paper, but also can't understand what the transmission cooler could have to do with the problem. Maybe the left tank is the weakest by design and for that reason is the first one to burst. But what could cause these pinholes? Is it maybe just a bad batch of radiators with some kind of material failure?
Sorry, but running out of ideas.
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  #24  
Old 07-19-2013, 11:39 AM
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Re: ANOTHER overheating WJ

You and me both! I just want to drive it...NOT fix it, especially fix the same thing 6 times in a month and a half.
New radiator is in this morning. I made sure NOTHING banged or touched the upper left corner of the radiator. So now if ANYTHING goes wrong, it's while the vehicle is in use. Not that it was an issue before, but why always in that corner??? I also don't see the issue with the trans cooler in the left side. Hopefully the new 16 PSI radiator cap will make a difference.
Unfortunately, I know I'll be back to respond to this post and most likely not with good news...trying to be positive, but so far only pretty positive I'll be replacing the radiator ....yet again....just how long will it take?
Maybe your right with the bad batch, We'll see.

Thanks for trying...
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