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More than likely the poppet valve was stuck, not the t-stat.... the water that is alllowed to pass by the t-stat dumps into the itermediate housing after flowing past the exhaust chambers and exists out the lower unit and acts as a muffler when it fills the tube ...it's a good practice to replace the poppet valve diapram, t-stat and water pump every 3-4 years ( I do mine every other time I re register), it's not just the use, sitting idle causes the impeller to take a set, the poppet valve also can stay seated in it's seat, and the t stats ( which are very small), get plugged and corroded..glad you got it working..
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