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I agree, regarding the cheap plastic. The new parts are of the same plastic. The heater is only a little over 5 years old. I checked the pump basket, but found nothing. Like you said, they are probably in the plumbing somewhere.

Here is a picture of the broken valve, and the piece that broke off inside the header. The piece that was broken off of the header was making all of the noise, as it is large enough so that it wouldn't fit through the outlet. I have no idea where the small pieces from the cone end of the valve went.

I ordered the bypass valve, and you were correct. The cone shaped end of the valve that I removed was destroyed. The problme is, it also broke the header inside (where the valve seats), so now I had to order a new header. That one hurts!!! The saga continures, but I am feeling more confident...

I will check it out. Thank you for your help.

Thank you for your response. I have removed the top of the unit, and cleaned everything that I can see and get to. I saw a bypass valve online...is that something I should be able to change? The intake and outlet of the blower are clear, and the blower seems to work just fine. The unit is about...

My heater seems to start just fine. Blower comes on for a short time on low speed. Then I can hear ignition and heat comes out of stack. After a short time, the blower kicks into high gear and everything seems fine. Then a hear something actuate, and water seems to be flowing out of the...