The 2 I have dealt with, have been exactly what you had mentioned, heat expansion when turned off (or also called heat soak).Both times I contacted our "smart guys(ya right) at technical assistance and they said they knew of the problem and didn't have info at this time, and that was some time ago.....
One thing that sucks, its one thing to physically have a failed part/problem, but its flat out frustrating when you are dealing with engineering type of problems like the pop...
certified H2 tech.
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certified H2 tech. troll 
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