found this post after doing my own autopsy on one of these. Like said previously the problem is the paint flaking inside the heater core.... mine was so full of flakes and mineral deposits that my pump wouldn't keep running due to reduced flow (almost none).
I suspect that some chemicals are eating away at the paint as the aluminum doesn't appear to be heavily pitted or otherwise damaged.
The paint flakes seem to peel away and hit the other side of the water channel, creating an eddy where mineral deposits and grit that makes it past the filter settles and build up... between the flakes and mineral deposits I couldn't see light through it, and had to use some force to get a long shift screw driver through the blockage.
Gonna buy a wire pipe cleaner to clean it all out and put it back together, bet it works a lot better.
Not sure why they painted the inside, seems to me raw aluminum would be more reliable
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