I keep hearing a light crackling sound when my subwoofer is on. It doesn't do it consistently but from time to time. I hear a small pop then sometimes a light crackle. This mostly happens when the sub is not at full power. I sent in the amp that powers the sub and everything checked out fine. Does anyone else have any ideas?
First change the sub cable, in case it has a bad connection.
Then if that is not the problem, either the tech did a poor job of checking out your sub amp, or he could not reproduce the fault at the time. (not unusual). It could be a problem with your receiver. My money is on the sub, as those switching power supplies so often used in subs are renowned for the types of problems you are describing.
If you can not live with the problem or it gets worse just ditch the unit. Those power supplies are a pain to fix and not worth the trouble.