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I believe BlueAngel reported less than optimal quality when molding his coolant tank. This system operates at 20 psi pressure. Any air pockets in the cooling system that cause the coolant to boil, raise the pressure even further stressing the plastic components. There's a GM ACDelco tank, and then there's a DORMAN aftermarket tank both sold on our forum sponsor Rockauto.com.

I believe the DORMAN one comes with a new cap. Does dorman know something about the failure rate of coolant tanks to make this part? I don't know. Maybe they redesigned it with reinforcement.

Good luck.. That seems like a lot of coolant. Check were the upper radiator hose attaches to the water outlet on the drivers side of the engine block, and the water pump for leaks.
 
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