Ok thought I would update the thread. Ambient temperature here has been upper 80's to low 90's. Coolant temperature has be 195 to 200. Subjectively the engine is cooler. The cooling system has been flawless. I have noticed the pressure of the system seems much lower, probably less then 5 lbs. I will continue to monitor it.
I will put a pressure gauge on the system this weekend measure it hot. With the old 195 thermostat and system hot it would routine pressurize to 10 lbs. after a highway drive or long idles.
Could it have been an improper ratio of antifreeze? Less then a 50/50 ratio causing the pressure to be less than 16lbs but going up and down causing stress in the seams? With a 195 thermostat my coolant temps were 200 to 210. When I changed the radiator the last 2 times I used prediluted Prestone green.
This time I measure how much I got out of the block and the radiator as well as the front heater core and then added Zyrtec g05 undiluted until I had a 70:30 ratio based on what was left in the rear heater core/lines/block.
This would not explain the failure from the dealer though. I can't imagine they were not making the mixture exactly 50:50. I don't think it would explain the leak being in the same locations each time either.
I checked the dilution with an autozone Prestone instrument and it said a 70:30.
Ok. I will post back in 6 months!!!
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