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I've got the same problem. It turrns out to be a leak in one of the metal pipes attached to the heater matrix. Most of the time the leak is not noticeable, other times it's like a fountain - something to do with changes in pressure.
The expansion tank is just that. As the coolant in the engine gets hotter it expands as you would expect. It has to go somewhere or the pressure will get too much and something will blow.
The radiator cap is a pressure release valve with a spring and rubber so that at a certain pressure the rubber pushes against the spring and allows water to overflow into the expansion tank.
As the engine cools it siphons it back. So the level in the tank will go up when hot and down when cold. I know where mine should be at hot and cold.
The pipe that goes to nowhere is in case the expansion tank is over full and gives it a way of escaping.
If you are seeing the level in the expansion tank go down It's due to the engine siphoning some back to the rad to replace what's lost. It might not have enough vacuum to get all it needs back though if some water and pressure has been lost in the system somewhere.
As you can't find the leak that's a problem. Pressure testing the coolant system might help you find it.
I suspect it might be the heater matrix as others have said but you don't want to strip the dash to find its not. I'd have thought you would have smelt the sweet smell of the antifreeze if it was though.
You sound like you've spent a considerable amount of time and money, some unnecessarily perhaps. I don't want to see you spend too much more though but it needs fixing. If I think of anything else I'll let you know. I would pressure test it myself somewhere quiet and listen for the leak. Thats opposed to paying a garage.
Kirkynut
The underdog often starts the fight, and occasionally the upper dog deserves to win - Edgar Watson Howe.
Just as another thought. I wonder if you've just got air in the system from draining it to do the head gasket. Did you turn the heater to hot before draining and refilling?
You could just be replacing the air that's working its way out with water at the moment. How many times/miles have you used it since changing the head gasket?
Have you heard gurgling coming from the coolant as you drive?
Keep using it and see if it settles down.
Kirkynut
The underdog often starts the fight, and occasionally the upper dog deserves to win - Edgar Watson Howe.
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