Don't forget the simple stuff. I just found 1/4" of HAIR covering most of my radiator fins on my '94 T-Bird this morning (didn't cure my overheating problem entirely, but it did help a bit). Loosen the top radiator mounts, tilt it back enough to look, and if it's covered in road debris, give the front of the radiator a gentle but thorough cleaning (I used a toothbrush to loosen the stuff and then sucked it away with a Shop-Vac).
Other possibilities:
- Clogged coolant passages (possibly from someone using a stop-leak product that accumulated somewhere in a clump);
- Leaking intake manifold passages (coolant burns off/evaporates before you can see it);
- Fan clutch defective/dead, or wrong-rotation fan clutch installed;
- 160* T-stat is about the same as not having a T-stat installed, at all - can result in overheating conditions, as well;
Be careful if you wind up having to replace the radiator, itself, and you spring for a heavy-duty unit. The brass/copper radiator from Autozone and similar places listed as an HD 3-core unit is actually a TWO-core radiator, now - you're still paying the price for a 3-core, but getting screwed for a regular 2-core that Go-Dan believes is "sufficient."
