I went ahead and replaced mine last night...havent heard the noise in several weeks but this thread got me thinking about it so I decided to go ahead and get a new one.... Ended up getting a Visi-Therm Stealth 250w for my 55g... Did the online price matching at Petsmart ...got it for the $20.99 online price instead of the $34.99 instore price :headbang2:
I too was thinking along the same lines of the popping noise maybe being some sort of condensation inside the heater...and that wouldnt be good if it were enough to cause the glass to shatter when it popped or shorted the thing out.... although I never have noticed any in the heater I figure I had rather be safe than sorry