Blower Motor “clicking“ sound?
 

Context:

2017 Toyota 86

So I had my Blower Motor replaced under warranty by Toyota about a year ago (25k miles) because it was making this “clicking” sound and the air coming from the vents seemed weak even on the highest setting. Toyota initially claimed it was the Blower Motor, but I’m now at 40k miles and I’ve been having the same issue recently to the point where the AC just goes completely out.

The warranty is now expired, and I’ve read through other sources that it could be the Relay going bad. I removed the Blower Motor and it works and sounds perfectly fine when I’m holding it in my hand while testing it, and it still looks new. But once I place it back under neither the dash, the same noise slowly comes back from the Blower Motor.

I checked the space in which the Blower Motor sits, and there’s nothing blocking it or getting in the way of the fan itself so I’m not sure what’s causing it to fail.

I ordered a new Relay and I’m hoping that’s all it is and not a major electrical issue.

Hoping someone has a bit more insight on the situation?

Here’s a Link to what it sounds like:
https://youtu.be/_oq_TD4Ncoc

have you replaced the cabin filter every other oil change(12k mi intervals)?

The last time I heard a sound like that - a plane was taking off.

What do you mean the AC goes completely out?

I have an idea that when the unit is re-installed in the car that the blower motor housing is being stressed/twisted so that the fan blade is hitting something - :iono:

Yes

I’m using a K&N washable cabin Air Filter, it’s good as new.

There’s no air flow. Hot or Cold.

For the past 2 weeks it’s been 50/50 on if the AC will work when I turn on the car, and if it does work, you hear a clicking sound and the air is weak. If not, there’s just no air coming from the vents. I’ve pulled out and inspected the Blower Motor at least 3 times, and twice it’s kicked on full blast in my hand with no sound and no issue, but just recently it hasn’t worked at all.

Maybe get a voltmeter and see if the motor has the voltage to operate when commanded (or not). The circuit is not too complicated depending upon whether you have manual or automatic controls. This might help determine if there is a motor or relay or other problem.

Well, if you're getting power to it and it's grounded and it don't run, Bubba says it's time to get another one from the wrecking yard - :iono:

Thanks for this.

I’ll take the time to look over it and possibly find a solution. Appreciate it.

Sounds like bearing failure.
https://www.youtube.com/watch?v=YClg7qNSmRQ