I would suggest you have the radiator and cooling system pressure tested . .another option would be to get a new radiator cap and try that. If you want to do a quick test for the radiator cap .. try loosening it to the first notch and see if your overheating problem subsides ..
SOURCE: 2004 Jeep wrangler 4.0 - 6cyl overheating
Yes, for the price of a thermostat and the real possibility of getting a faulty one (that won't open or won't open fully) out of the box, I'd try another one...
If it still overheats, the water pump might be a probable culprit. It might not be sending enough water flow to cool the engine. Even with the thermostat fully open, it still restricts the water flow compared to no thermostat at all... When you take it out, it might flow enough that the engine does not overheat anymore.
Check your water pump and also sometimes a radiator flush is not good enough more than likely the radiator is blocked you have take to a radiator expert and have pulled apart and cleaned thoroughly
SOURCE: Engine overheating at high rpms
check the casting on your replacement water pump..4.0l engines require a reverse rotating water pump..may be causing your problem.
SOURCE: 1990 4.2 Jeep Wrangler that is overheating
Still sounds like a bad radiator...new or from scrapyard? If you can't add coolant faster than a really slow dribble that's a big clue.
You can run the engine with the heater on high and the engine should not air-lock. I'd also remove the thermostat just to make sure it is not defective. Run the engine without it and see if it still overheats. Last, it is possible that your head gasket has failed, and engine compression is causing the overheat. I tend to think not only because the hose stays soft.
While it's running, also make sure that the lower hose is not "sucking in" if it is, replace it. On 4.0 engines you can also get the serpentine belt on wrong and it will drive the pump backwards. if you replaced the belt check that too.
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SOURCE: overheating I change waterpump, thermostat,
Sounds like your radiator fan is not doing it's job. At highway speeds, there is enough air flowing through the radiator to cool it, without a fan. On local streets at slow speeds, the fan is necessary to draw air through the radiator, else you will overheat. Check your fan, either clutch fan or electric fan, to see if it's working as it should.
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