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Timely thread - I seem to have recently developed the same type of rattle. I'll poke around with a stethoscope this weekend to see if I can isolate where it's coming from.
I can concur with the previous warnings about the plastic nipple on #1 breaking. Also, any pipe (or temperature sensor) you disconnect needs to either be replaced or at a minimum its o-ring replaced, as the old ones will be hard and flattened and will surely leak when reconnected.
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