After replacing the heater I noticed an increase in airflow which was not initially recognized when the noise started. When I removed the grate I also noticed that the plastic around the heater had melted. This seems to indicate that I had to replace it because of the reduced airflow rather than the annoying noise. I'm a handyman/DIY enthusiast and this was a lesson for me. My unit was over 20 years old. Glad you got your units back!
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