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Last night I replaced the Wahler thermostat (that was new from ipd) with a Calorstat 158'F thermostat. The Calorstat has a different bypass valve design, and once I put everything back together and filled up the radiator to the top with the engine running, coolant started running out of it, and now there's pressure in the expansion tank too. This didn't happen with the Wahler thermostat. So I'm assuming it was defective.
Went for a drive and now the temp stays in the middle (creeps up towards 3/4 at idle), but on the highway stays steady at 1/2. Glad I don't need to waste $500 on a new radiator just yet :)
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