After trying everything to fix my Fluval 406 I posted a video asking peoples help with my issue. I found the issue, and created a free and easy fix. Now its air-tight and im happy :-)
Things I did to try and fix before this video:
Did impeller replacement kit with housing
All seals replaced
Used Fluval silicone on all seals
Swapped all hoses
No air bubbles from tank into intake
Filters are clear, and all media is flowing well