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Originally Posted by camcojb
Keith,
You might also try removing the inlet filter if it's easy to do. Any restriction like that can cause cavitation at the pump and would not show up immediately, but after running and heating for a while. If that cures it replace the filter with one with a much coarser filter and use the fine filter for the pressure side. You do not want any restriction on the inlet side of the system.
Jody
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Hey Jody-
We had the filter removed before in a troubleshooting teardown and it was the same problem with or without it. We're going to beat this!!