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94 Ranger, 4.0, 5sp. Been having problems with the coolant boiling over into the recovery tank. Replaced radiator with new one last year and had system professionally flushed. Helped for a while, but the problem is back. Sunday I replaced just about everything else with the exception of the water pump and lower rad hose. Replaced heater core, both heater hoses, new tstat (180), upper rad hose. Flushed it all out as well as I could, filled it up with water and radiator flush. Gonna flush it all back out today and refill it with proper mix of water/coolant. The problem is it's still boiling over. The guage never gets hot. It actually reads cooler now, due to the 180 tstat (it had 195 in it before). I just can't figure what the problem is. Maybe gunked up passages inside the block? Could still be something with the water pump maybe... I thought I'd try changing that next just for good measure.
Check the pressure rise while the engine warms up. You may have a blown head gasket etc a common problem with that engine. Use the proper thermostat, not a 180°F unit.
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