Finally figured it out... one of the fan blades was slightly longer and was just touching the plastic support bracket that holds the fan shroud on every revolution. I shaved it down a hair with a file and so far so good.
Yes, as the fan clutch kicks in the fan spins faster and flexes hitting the shroud. Just reach in there with the engine off and spin the fan blades backwards and the one that catches is the longer one that needs a little sanding/ filing down.
@@xlandscaper Only place I can see it getting close enough is to the top support braces of shroud. Less than 1/8" clearance it seems. Also some of the fan blades have some excess material still attached from when the were molded.
I Can’t seem to figure it out, everything looks fine. When I take it in for the 1st oil change and the block heater recall I’m going to have them fix it.
