DJ, what you report is very unusual. Not being able to set the sub level low enough even with both the receiver sub channel and sub volume controls(not a "gain" control)set to the minimum is puzzling. Has this just developed recently?

Does the sub volume control appear to change the sub level at all when you change its settings? If not, it's as if it was disconnected and was letting the maximum voltage in regardless of the setting.

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Enjoy the music, not the equipment.