Is pool auto-expansion just broken by design now?

Nope.

The pool was created long before the release of 24.10.2, but a newly-replaced (currently resilvering) drive is partitioned this way:

sdaf         65:240  0  16.4T  0 disk
└─sdaf1      65:241  0   5.5T  0 part

Note also that there’s no swap/buffer partition created.

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