Hey bud, sorry to hear about the bad news. I have an 04 ZTS with the 2.3ltr Duratec, and after a year and a half i FINALLY fixed my overheating problem. Ill just explain what all was happening, what i did to fix it and hopefully it helps ya out. I bought the car in march still fairly chilly up here in Montana. thought there was nothing wrong with my car. Well first went the waterpump. the seals on the bearing shaft failed and i was blowing all my coolant out through a weep hole on the side of the pump housing. Bought the pump from NAPA for $45 and with my trusty Chiltons and 11 hours later i had it fixed. After this i found my car would still overheat. And what would happen exactly was it would be fine untill it was a hot day out, say above 75, and if idleing in stop n go traffic, or the drive-through it would start to climb into the red, well from trials i learned that with the A/C on the secondary fan comes on and would cool the engine back down. No leaks anywhere, knew the pump was working correctly cause of all the pressure in the top tube when i squeezed it while the engine was running. Onward i forged. I replaced the thermostat (which is in this stupid housing, I.E. special and from the dealer for $60!!!!!). Still overheats. then i started thinking that maybe it wasnt overheating at all and that it was just a bad CHT (cylinder head temp-sensor) so i did that too. Nope still did it. Right around this time i beacame a newbie to FJ, (love this place), and i explained what was doing on to the tech team and low and behold there is a "Engine Cooling Fan Resistor" on the bottom half of the fan shroud inbetween the two fans, and it was bad. Its supposed to control the secondary fans normal operation, either turns the fan on when the engine temp warrants it, or whenever the A/C was on. so if the resistors bad the only way to mimic normal opp. was to run the A/C. Hopefully this helps you out. And see what the tech department thinks, and check out my original thread in there reguarding all of this. Hopefully i helped ya out, let me know -K-
