What is the outside temps when it is running at 240? Is the 240 at 60 mph on a flat slab or hill? Does it actually reach 240 at idle or 210 at idle? When you put in the new thermostat did you check it in boiling water first? Does it open at least 1/4 in.? When you checked the temps with a IR gun did you compare the temp sensor in the L/H head to the thermostat housing? The fan clutch should roar when you first start the eng then disengage and stay in free wheel until the air temps at the coil spring on the front of the fan reaches about 160 degrees F. This should not occur unless the outside temps are above 80 or 90 or you are hill climbing.