Time to get a new water filter. I decided to shelf the Katadyn Vario and pick up a Sawyer PointOne.
The Katadyn Vario has had a number of issues, such as leaking around the head. The final straw was when the hinges on a pump piston broke loose when checking my gear.
I was getting ready for a hiking trip, going over my gear, picked up the Katady Vario, looked it over, worked the handle, and the plastic hinges that work one of the pistons snapped. The hinge did not break, they just came out of their notches.