Dave:
Just for sh*ts and giggles, you might wanna try re-tinning all the solder joints on the pc board, jacks, sockets, etc. Sometimes you get a cracked or cold joint and a re-tin will fix the problem. While you're at it, you can tighten every mechanical fastener in the thing and make sure all your grounding/bonding is continuous. Look for any obvious signs of corrosion at any connection (electrical or mechanical), especially chassis grounding points and the chassis fasteners themselves. The chassis must be all at the same ground potential or noise current and/or intermittent operation will result.