Sounds like you could have two issues. The first of the noise, smell, and fogging of the windows is a leak in the heater core. Basically you have coolant in the HVAC system and when you have the air on, it is blowing steam from the coolant into the inside of the vehicle.
As fro the sludge under the cap, can you get a picture of it? You are correct that it is most likely a cooler issue or a head issue. Here is a guide on how to check the head gasket:
https://www.2carpros.com/articles/head-gasket-blown-test
Once we rule this out and get a picture of it we can get on a possible cooler issue. However, we need to go step by step so let us know what you find. Thanks
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Tuesday, September 1st, 2020 AT 6:18 PM