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It sounds like something is blocking the "squirrel cage". My fan used to grind against the casing because the rubber mounting bushings shrunk over time. I added a simple washer to the spot between the motor and the rubber bushing and the problem went away. Since you will be removing the heater box anyway, bench test the motor. If it is bad, OGTS should have spare units. I got a used heater cable from them(the one which controls the valve in the engine compartment) and it works fine. just my 0.02 cents:)
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