I feel your pain OKguy!
I am now on my second 6025 powerhead. I love the look of the powerhead and the flow pattern is perfect, but they seriously dropped the ball in testing and quality control!
It's frustrating that people are having trouble with their second set of replacement powerheads. Do your powerheads have the new round power cord? Apparently, this is the new "fixed" version of the nanostream.
Oh yeah, I had to modify my new powerhead straight out of the box just to get the front cover to stay on. It still looks pretty loose though. Has anyone else had trouble securely fastening the front cover on their second nanostream (round cord)? How did you fix it?