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How much are you filling the overflow tank? What level does it drop to after it pukes? If I fill mine too much, it does the same thing until it reaches its equilibrium point, which is only .5"-1.5" in the bottom of the overflow tank. More than that an it pukes. But as long as you have anything still in the overflow tank when it's cold, I think you are fine.
So let it puke and see where you are when it cools down.
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