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Look for black pieces of foam in vent outlets. From what I've read it is not uncommon for the foam in the AC/heat control box to partially disintegrate w/age. I suspect that may be your issue. I had a similar issue and just pulled the flakes from the vents w/ hemostats to eliminate the noise. Heat and a/c still perform well so I have not tackled the real fix of digging into control box (big job).
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