Next item to rear it's ugly head is an issue with excessive heat and high temps in the engine bay.
While both the Dakota Digital and Sniper show engine temps to be right at 190 degrees (stock OEM 190* thermostat) when driving, at idle they climb slightly and the engine bay gets so hot that you cannot touch almost anything metal. Neither the 40 or the 60 are like this.
Since the 45's cooling system is 100% new parts and the problem is worse at idle, after research I believe that the heat issue is an airflow problem caused by the fan being completely inside the shroud. Both my 40 and 60 have 1/3 to 1/2 of the fan blade outside the shroud, and have no issue with engine bay heat.
The fan is farther forward into the shroud because I replaced the original non fan clutch with a new water pump/fan clutch/fan blade assembly that moved the fan forward about 1 inch -see post 77 of this thread.
I will not have time in the next week to work on this, so in the mean time, I look forward to some good MUD input.
