Jeep 2002-2006 Wrangler Heater Core
Jeep 2002-2006 Wrangler Heater Core
Jeep 2002-2006 Wrangler Heater Core
Jeep 2002-2006 Wrangler Heater Core

Jeep 2002-2006 Wrangler Heater Core

HC 02-06 Jeep Wrg 20FPI-2.625

Regular price $375.00

Oh No!  Your aluminum heater core in your 2002-2006 Jeep Wrangler failed again because of electrolysis. We were asked to make the core of copper due to the repeated failures of the aluminum and the aggravation and high labor cost to replace it.

Most heater cores perform well at 11 fins per inch.  Jeep guys wanted more heat so we added a 15FPI and then a 20FPI.  We noticed some Jeepers bought the lower price heater core and then went on forums to complain.  They spoke, we listened.  We now only offer a 20FPI and we are now offer an oversized 2-5/8" thick core in the box.  

There is a lot of forum chatter about heater core design and heat exchange. 

  • Turbulators serve to introduce hot coolant to a round tube wall because absent them, most of the fluid would touch fluid and not exchange heat.  Turbulators are not used in a highly efficient "flat" tubes due to the superior geometric shape which allows significantly more wall contact. 
  • We do not make the tubes or fins of aluminum. Copper conducts heat faster.
  • Baffles route the fluid flow within the tank. 
  • Some cooling system heat exchangers restrict flow for pressure and core longevity.  Whenever the aggregate tube array is greater than outlet, there is a flow restriction.  

The Jeep's engine was intended to run at temperatures of ~210 degrees.  Changing a thermostat, adding a high flow water pump, putting in a larger radiator will ultimately reduce the system operating temperature and this may affect the heater core's heat output.  Additionally, Jeep heater cores can become clogged with "sludge", mice love living in vents and snacking on wire coating and blend doors do fail. We make a more efficient core with the limited space provided and try to help people understand their heater core's design better Some listen to us and some hang out on forums.

  tube shape tube count Vol in quarts Major OD tube wall thickness tube wall area
OE round 7 .19 0.3 0.028 0.40
BW elliptical 11  .58 0.75 0.007 0.49
    157% 305% 250% 25% 122.5%
  fin material thermal conductivity fins per inch agg. area Cu. Area net area
OE AL 205W/m K 21 1,459 4.38 1,458
BW 2r Cu 385W/m K  20 1,464 4.32 1,461
BW 3r Cu 385W/m K  20 2,121 6.26 2,083

 

The heater cores are made to order so please allow adequate time when ordering.


We make to order. Please allow adequate time for us to build.

Build time estimates [Feb 2025]

Brass/Black Model Ts

Our longstanding foundry (supplier) closed and all production was shifted to a neighboring foundry.  Apparently many of the closed foundry's workers were ineligible for rehire by the new foundry due to more aggressive immigration enforcement and the union has no employees to provide.  As of 2-20-25, we should receive castings in March 2025 and can resume production then. 

In the interim, we have been working with our one-off foundry to have pattern boxes made and these are trickling in in smaller batches and we will produce what we can.

Model As 5-6 weeks

Heater cores ~6 weeks

Model A and 32 Ford Street rods 6 weeks

Common street rods ~12-15 weeks

Tricky customs & complicated restorations ~16 weeks months

We appreciate your patience as we continue to recruit and train new fabricators and manage the labor shortfall our country has been experiencing.