Thermostat replacement and/or hood louvers?
Has anyone tried replacing the thermostat on an overheating FiST? It's only a $47 part (Part Number: 8575(RH-223)), though installation looks a bit involved.
My 2016 FiST with 20,000 miles has come close to overheating on three occasions, each time requiring that I turn on the heater to get temps back down. Each time the ambient air temps were 95 or higher and I had the A/C on. Twice I was going uphill on winding roads and once I was in stop-and-go traffic after hours of 80 mph highway driving. The general problem seems to be that once coolant temps get above 220 or so, the car can't keep itself cool without lots of airflow, no matter how how much the radiator fan runs.
My FiST isn't stock. I installed a Mishimoto J-line intercooler, which is thicker and hangs lower than stock. I have a Mountune tune, which removes restrictions on boost in 1st and 2nd and allows boost up to 24 psi. I have a Boomba Racing CCV catch can and a Mishimoto PCV catch can, though I relocated the later to the passenger-side strut tower to eliminate the possibility that it was restricting airflow.
My oil temps (according to the Accessport) can reach 250 when highway driving in 100 degree temps. I run Mobile 1 5w-20. I added an oil pressure gauge that necessitated installing a sandwich plate between the oil filter and engine. This prevents one of the radiator shroud flaps from opening fully.
On my car, the fitment of the A/C condenser, radiator, and radiator shroud assembly is poor, i.e., there are lots of air gaps. Ford saw fit to "seal" the gap on the passenger side between the condenser and the radiator with, basically, gray foam weather stripping, which fell off. I made an aluminum bracket to re-seal it.
It's possible that my intercooler is to blame for the overheating -- I've tested the car without the tune and the overheating persists -- but, even though the intercooler is larger than stock, there are no airflow restrictions above the crashbeam. When I installed the intercooler I retained the radiator air deflectors (Part Numbers: 8310A, 8310C, 8310E, 8327A, 8327B), but airflow is a dark art, so perhaps I fouled something.
A new radiator is tempting, though it feels like that would sort of be blindly throwing money at the problem. I like that the Mishimoto does away with the stock fan/shroud assembly, given the bad fitment on my car. I would happily take a 2-inch hole saw to my car to make low-fi hood louvers, if I were confident that would help.