Blower Motor Noise

[Lej512]

If it isn't one thing, it's another with this Bronco. 2023 BD Sasquatch, 21k miles, never been off road, rarely gets dirty inside or out. (Judge me if you will) Had the top replaced a few weeks ago. In the process, the body shop broke the connection to the rear defroster. They had to order a new rear glass. Fortunately all under warranty. Today, temps are in the 90's so I fire up the A/C. When I turn the fan to "7", I can hear this obnoxious, low pitch humming - similar to road noise caused by coarse tread tires. Never heard it before. It changes with the fan speed so I suspect it's the blower. I pulled the cabin filter, all good. Installed properly. Noise is there with or without the cabin filter. I cycled through the vent settings, I can hear the dampers opening and closing and the noise is still there. I turned of the A/C and ran the heat making the same adjustments and the noise is still there.

Any ideas before I send it for yet another visit to the dealer?

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[shaw]

If it isn't one thing, it's another with this Bronco. 2023 BD Sasquatch, 21k miles, never been off road, rarely gets dirty inside or out. (Judge me if you will) Had the top replaced a few weeks ago. In the process, the body shop broke the connection to the rear defroster. They had to order a new rear glass. Fortunately all under warranty. Today, temps are in the 90's so I fire up the A/C. When I turn the fan to "7", I can hear this obnoxious, low pitch humming - similar to road noise caused by coarse tread tires. Never heard it before. It changes with the fan speed so I suspect it's the blower. I pulled the cabin filter, all good. Installed properly. Noise is there with or without the cabin filter. I cycled through the vent settings, I can hear the dampers opening and closing and the noise is still there. I turned of the A/C and ran the heat making the same adjustments and the noise is still there.

Any ideas before I send it for yet another visit to the dealer?

That definitely sounds frustrating, especially after just getting it back from the body shop. If the humming changes with fan speed and is present with both A/C and heat, I'd also be leaning toward the blower motor or something rubbing against the blower wheel. It's possible some debris got into the housing while the repairs were being done, or the blower wasn't reinstalled quite right if anything in that area was disturbed. I'd have the dealer take a look, especially since it's still under warranty. Hopefully it's something simple and not another extended repair.