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gotta love subs.....if they aren't built right they're a pain in the a**. I remember building a cabinet for my car's sub, and it was so powerful it was even blowing air around the screws.
the distortion could be caused by the leaking air, or the woofer itself could be worn out (you mentioned it was 6 years old, right?). Re-seal all the leaks like dj_alfi mentioned, and if that doesn't stop the distortion, you may have to replace the woofer.
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