Ok, so the second time in into the blower motor in 100k (car is now at 321k mi) and I have a weird problem...

The replacement blower motor seems to be out of alignment. So that on the right side (passenger's side), the front part of the fan blade (closest to the firewall) is rubbing against the inner housing. No visible issues with the shaft being off-center. I've pulled and re-seated the fan and the shrouds several times. At high, you can hear the blades contacting the inner housing only on that side, in the front.

The motor is from FCP Groton (had it for about a year), replacing a Siemens I got from RPR about 6 years ago.

This has turned into one of "those" jobs as I have pulled the whole dash and am also replacing the condenser (got the Volvo 134 conversion kit from FCP), thought I'd dress the wires, and also thought I'd replace the radio with a new Ipod compatible jobby. Yeah, like this was a lazy Sunday.

I checked the driver's side and made sure that the ballast bracket was not between the housing and the motor to add more shim. Not quite sure what's going on. Don't want to use washers between the housing and the fan on the two remaining screws because that may level out the fan, but put it very close to the inner housing for problems down the road.

6 beers and so many hours into this project, I might shut it down until tomorrow.

My god, butyl, butyl everywhere! WTF is with all the butyl?!

Thanks in advance if you have any suggestions.

...Brian...