Hello all. It's been squite some time since I've posted but I visit this site daily throughout the week when downtime allows at work. Here's an apology up front about the length and whineing that is to follow. Last September the old 2.8 started choking on a bad rod bearing. For the past couple of years I've been thinking of the 3.4 swap and thought this the perfect opportunity. Anyway found a shop, found the engine (salvage with 60K supposed miles), gathered all needed parts and delivered it all. Now I could go on about how pathetic these guys turned out to be, but that's not important. Got the truck back Friday. The thermostat was locked so they punched it out (you know, since I wasn't there to buy one for them). Without doing that they couldn't let the engine run. My patience had worn about as thin as my hair so I decided to take it and work through all the bugs myself (actually get it to my hometown to people I trust - couple hundred miles away). So from the shop to my place (30 miles) that sumbitch got hotter than I have ever seen it get. Hot to the point that as I pulled over (bout 2 miles from my house) it just shut off. Waited, refilled radiator, drove home. It ran great until I hit the redlight so it's dependant on airflow to stay cool. So the fan clutch was my first thought, it's old. So is the radiator, 249,000 miles old to be exact. So I waited for it to cool off, changed to a new, functional thermostat, refilled the radiator and drove about 40 more miles. Same thing, hotter than haites. Concluded that as long as I was driving at least 45-50 mph, it would stay cool. Also determined that the engine still had some air trapped inside because of the lack of heat flowing from the vents. So Saturday morning I took off for the trip back to the hometown. Truck ran great, as long as it was moving. Felt damn good to be sitting behind the wheel again, but felt horrible not knowing what was going to happen on the way home. Had to stop once and of course it overheated, so I let it cool, refilled the radiator and drove on home. Made it in one piece, pulled into the drive with the temperature hand sitting on a solid H because of having to negotiate stop signs and little old ladies driving volvo's. <img src="/forums/images/graemlins/angry.gif" alt="" /> Of all the things that I think could be making this thing overheat; air in the system, old radiator, fan clutch shot, blown head gasket or cracked head <img src="/forums/images/graemlins/scared.gif" alt="" /> , I was wondering if the guru's here could lend some info or opinions. The oil shows no water in it, nothing is leaking from the heater core, no antifreeze smell inside the vehicle. Every time I refilled the radiator, it would take up to 60-70 oz of water. Another concern I had, not related to overheating. While the 2.8 was still in, the oil cooler hoses started leaking from where it attaches to the block. These same mechanics used an adaptor that was slightly modified to eliminate the oil cooler. This was by my choice, but I was wondering if that is ok. Essentially, it just blocks ability for the oil to flow from the outlet and back into the inlet. If those two holes are blocked, will there still be oil flow throughout the engine or will it stop right there? I know that was a little confusing but I don't really know any other way to explain. So, if your still reading this, here's comes the main questions:
1. Is my old radiator, or a new 2.8 radiator, going to be sufficient to cool the 3.4?
2. Where could the water be going? It doesn't appear to be leaking from anywhere but the over flow cap (little spout) when up to operating temp.
3. Will my 2.8 heads work on this engine (3.4)?
4. Will electric fans be a better choice instead of buying a new fan clutch?
5. Is it useless to put a 4.3 TBI without boring the intake?

Again, sorry for the length of this. Any help you guys have is appreciated. I really hope to be sharing some good news and pictures real soon. It's been killing me the past 4 months to leave my truck in the hands of some guys that I don't know. I moved to this area about a year ago and have regretted taking it anywhere but places I know of back home in the first place. It's a bit hard when you don't know the reputations, don't have a shop anymore and your DD is about to throw a rod bearing. At that time I lived about 30 miles from work and was getting pretty damned desperate, afraid I might lose the job I moved here for cause I couldn't get to work! But anyway my father has it now and has already flushed the system to elimiate the airlock and found a 93 Astro 4.3 TBI and injectors to put on. He's mostly worried about a cracked head or head related problem. Thanks for taking the time to read and respond if you can.

JC