@gbennett21
FIRST: On your 2003 Jeep, (same on the 2002) looking down on the hoses from the engine compartment: the hose on the LEFT in the COOLANT OUT HOSE, the hose on the RIGHT is the COOLANT IN HOSE. (Can't remember sizes.)
(We thought we'd put up the direction of coolant hoses to your heater core, as none of the previous posters gave you that info, even when you asked them 3 or 4 times.)
Hi there G,
This is a GREAT topic as we have the same problem!
We did ALL the changes you did, even used a Mishimoto racing thermostat, (they kick in at lower HIGH temps, tested in the hot water basin first before install).
We also have 2 Jeeps a blue Jeep like yours and a white one.
All the parts we bought we tried out on the white one first, and when it worked awesome, we transferred those exact same parts into the other Jeep, core, thermostat, rad, plenum c/w heater core, vac hoses, vac pack, vac dash kit, reservoir etc, even the same engine hoses, same problems you've got! Even the pressure test came back great, holds with NO problems!
There must be something we're missing!
We're lucky to have 2 Jeeps we can try and solve problems faster by comparison from one Jeep to the other.
One poster said something about sealing surfaces, but after looking at our notes, ALL sealing surfaces are fine.
Another poster said that there may be a coolant valve, NO such valve exists on any of our Jeeps. No control valve either.
We initially thought that there may have been some idiot that put in GUNK in the reservoir to fix a leaky rad, (we're not 1st owner, we're 2nd) and that stuff is deadly for cooling systems. Possibly, but nah!
Grew up with Barrs, much better fix and it's been around since the 1940's.
But installing a complete system, and taking it out and installing it again in the 2002, and no change we just gave up for the time being.
It's a tricky one for sure, (and a pain in the butt) maybe now we'll take another look.
BTW, (A/C no leaks, Freon, NOT propane, works great! And ALL Plenum doors fully operational)
NOTE: We also noticed, in case you missed this on yours, underneath the outside vent where the wiper blades go, we were told by the dealer's mechanic that there was a filter we have to change. So, we removed both wiper blades, and took off the plastic cowling at the front outside of the Jeep where the wiper blades came off, (be careful taking off the plastic clips), NO filter exists, but was slightly dirty, vacuumed it out, but nothing serious.
Main parts of the heating system:
and lastly the:
Ambient Air Temperature Sensor.
*Did you check/change the, "Ambient Air Temperature Sensor?"
Please keep us up to date