Just for experiment sake, before you unmount the winch, take off your headlight bezels, and do a hwy lap like that and see if you get cooler temps.
If you could pare down the winch mount frontal area, and relocate the electric box, that will help a little.
I may relocate the solenoid box but I most likely won't take the winch off unless I plan to do work on the front end. It's not my daily driver and I rarely go on long trips but I don't want to be hindered at highway speeds.
I thought about aluminum but I would prefer brass. I've had to pinch and crimp brass cores before and it barely leaked afterwards. I don't have experience with aluminum but I feel it may not have the same qualities depending on the heat treatment of the metal.
Time to chop out the frame crossmember and sink that winch down between the frame rails. I sometimes forget how big the 8274 is, and the huge mount plates don't do you any favors either.
I'm debating this. I just need to figure out what to do with the steering box. Maybe build around it and see if the winch will fit in between. I don't see a need for it to be dead center, just close.
Do you have room for a 3 row? I have a two row and the water pump bolts are thisclose to the Taurus housing.
I get hot on the highway sometimes going up a long hill and kick the fan on high, which does help.
Normally there is no need for a fan at all at freeway speed but I think with the turbulence caused by the winch having the Taurus running full blast probably does a good job at steering the air in.
I have an XJ pump with the flat flange which gives me about an inch or so more than the stock YJ pumps. If push comes to shove, I can trim the shroud thinner.
This interests me. You said earlier that at higher speeds, you heat up, yet under the same ambient temps you are fine crawling.
I'm wondering if the blade pitch of the XJ Water pump as well as the Circumference of the flat flange water pump pulley are the issue.
At higher RPMS constantly, you may be not moving as much fluid due to the blades spinning too fast if the pulley is smaller than your stock size, even by just a 1/4 inch. This would be a benefit at lower rpms or short bursts of rpms while wheeling, but a definite drawback at higher speeds.
You may just be causing your cooling system to become less efficient at sustained high speeds - ie, not moving enough fluid. If your impeller is spinning at a rate that, due to it's pitch, creates a situation werein you are at low operational efficiency, the liquid doesn't move well.
As far as the impellers between the two I'm not sure. As for the diameter of the outside pulley's, I believe they are nearly the same. The main difference being the pushed out center of the YJ one. If I could find a smaller pulley that would fit it would increase my rpm's but I may be better off getting a high flow pump if I want to pursue that path.
Something else that came to mind, I have a Taurus fan that covers 85% of the back of the radiator with the bottom 3-4" with no fan coverage. I may try to find a Mark VII fan or Volvo fan and get it to fit the entire backside. See below.