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There is a chance some of the foam liner inside the hvac system has fallen off and is hitting the vanes of the blower fan (baseball car in wheel spoke effect). Have you notices other bits of thin, dry grey foam spitting out of your air vents?
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kabel
Orlando - 99 BMW M Coupe (autocross toy), '11 Mazdaspeed 3 (dog hauler), '99 10AE Miata (the new daily driver)
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