Mine is doing the same thing. I haven't found a fix but I can tell you a few things that don't work: putting thru a mixture of vinegar and water and hitting the steam burst button, physically cleaning the steam ports with a q-tip, banging the iron on the board (this was the most effective). The only thing I have left to try is putting a mixture of CLR thru it - but that may ruin it and forever put that stuff on my clothes! Heading out today to see if I can get a new one, current T-fal iron lasted 10years!!!! It doesn't owe me a penny, but I love her!
Greg - Mr. Iron Man
September 2009