[jeff_banning]

I had a mud dawber wasp nest in my blower motor that caused this on a rear air. I had to take the cover off, and take out the screws holding sheet metal around the blower motor and bend it back to get my hand inside. Cleaned out, screws back in, cap back on, fixed.

Same happened on furnace blower, it is a real bit*ch to get out.

May not be your issue but I have seen this twice now.