Hello,
I have 2 Fluval 404"s & have pretty much rebuilt mine from top to bottom more times than I can remember. Usually the rattling noise is,the round plastic cap that holds the umpeller in. It's either cracked some where, or check the two tabs on each side that it clicks in are not deformed. If its slightly raised on either side it wont hold the umpeller in even and it will rattle like crazy. You will also lose water pressure if it is not seated properely. I always have an extra one on hand for emergencies when doing maintenace on the units. I actullly had to use a self tapping screw to hold one side in because the little plastic tabs that hold it in were wearing out and it wouldnt hold the round plastice piece evenly anymore. Hope this helps!!
teresa