Is there anything that can cause the transformer to overheat and melt inside? The noise was caused by a vibration of the plates inside the transformer.
Does anyone know how hot the input transformer can get?
@filipm To the first comment (sorry I didn't catch this earlier), to my understanding ARC uses 'EI' core transformers for their power transformers (its not an 'input' transformer).
Over time, the bolts holding the transformer together (not the ones that secure it to the chassis) can loosen up. This is because they are insulated from the transformer by nylon washers, which shrink over time. If they get loose enough, the transformer can rattle. I suspect, since the amp was running this whole time, that simply tightening these bolts (there are four of them) would have solved the problem.
EI core transformers are quite resistant to DC on the power line. It takes quite a lot to make them rattle. Toroid transformers OTOH are quite sensitive!
Live and learn...
Regarding the second question its normal for the power transformer to run warm. 80C is fine. If the transformer gets so hot you can't touch it that's bad, but 80C is acceptable.