We had the squirrel cage fan break last year, and it was loudly rubbing on the inside of the foam enclosure of the unit. I was able to order a new one, and it only took about 15 minutes to replace. Possibly your fan is contacting the foam and is wearing away the fan material.
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Bob & Becky
2012 3402RL
2012 Chevy 2500HD D/A CC 4WD
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