OE plastic-tank/aluminum core radiator fails at tank seam. Brass/copper or all-metal upgrades from Champion 3-row, Griffin, or Mishimoto for hot climates and trail use.
Factory XJ radiator is a plastic side-tank with aluminum core. Failure modes: plastic tank cracks at the upper hose seam, internal tube clogging from scale, and gradual loss of capacity. OE replacement (Mopar 52028381 or Crown 52028380) is fine for a stock build. Upgrade options when overheating is chronic: Champion CC2101 3-row aluminum ($200-250) with plastic tanks but more cooling capacity; Mishimoto X-Line ($350-400) all-aluminum with TIG-welded tanks; Griffin custom-built ($350-500) with various core thickness options. For trail rigs running low speed in 100 F+ ambient, the upgrade is worthwhile. Pair any radiator upgrade with a checked fan clutch and a verified-good auxiliary electric fan (or upgrade the e-fan to a stronger Taurus or VW unit - popular swap). Radiator replacement: drain coolant, remove fan shroud (held by clips or screws), disconnect upper and lower hoses, remove four 10mm bolts at the radiator support, lift out. Avoid bending the trans cooler lines on the AW4 radiator versions.
| Part | Vendor | Est. price |
|---|---|---|
| OE replacement radiator | Mopar/Crown | ~$120 |
| Champion 3-row | Champion Cooling | ~$240 |
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.