Could be that you've got a head gasket problem and are lifting the 16# cap. First off, check to make sure that the overflow cannister's drain hose is not plugged (blow thru it). Then make sure the hose from the filler neck to the cannister isn't plugged. I had this happen before and blew all the compression out through the cap. Discovered that the hose from the filler neck to cannister was clogged. The excess pressure from blowing compression into the cooling system had nowhere to go but out the cap.
I have also seen the braze between the filler neck and radiator develop a crack. Check there too.
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Jeff Chambers
1990 Mustang GT 10.032 Seconds / 137.5 MPH
14-time Street Warrior World Record Setter
CRT Performance
2001 Tropic Green Mustang GT - 12.181 / 113.2 MPH
2002 Ford F-250 Crew Cab 7.3l Power Stroke - 17.41@77.2
"There's nothing boring about a small block automatic shifting gears at 9400 rpm!"
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