[WinDancer]

Schucks Auto Parts had a new housing [polished billet, all they had] for the truck.

Auto Zone had a pressure tester that they loan out for free! I didn't even buy any parts there. They just moved up on my list of where to go. They charge you the cost of a new tester [$75], then refund in full when you return it.

SOOOOO

I installed all the parts [the new housing has an o-ring, so no gasket. The o-ring seemed to droop when you turned it to the install position so I added a little tiny bit of grease in the o-ring slot and that held it while installing it], brought the motor to operating temp with the cap off, then installed the new cap.

I let the truck run at idle for about 30 minutes and it got warm but not hot- still burped a little water when the coolant got hot- then settled down. The water in the radiator at this point was not hot- I dipped my fingers in the radiator and the water was still cool. The heater hoses were all very hot- lots of heat from the heater.

I drove into town for gas after all the idling and the temp never got past normal.

Not sure if it is 'fixed' yet or not. Will drive it to work for a couple of weeks and keep a close watch on it.

Thanks to all for your thoughts and suggestions!