Thanks for the ideas...
I have a new wiring harness and don't think voltage to the fans is an issue, but I will make sure.
I did drill the thermostat - the FrontRunner instructions told me to do that. Would that ensure that no air pockets exist, or would you recommend still filling the block first? I agree that an air pocket sounds like it could be the culprit, I'm just not sure how it would have gotten in there if it had been fine before and not having filled the radiator recently.
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