MyE28.com

I bought and installed a brand new interior AC fan last summer. It was blowing great, but recently I heard a rattling / clunking sound, as if something fell into the fan from above and now I have the dreaded fan squeal. It still blows with lots of power, but the noise is unbearable.

I've read about applying lubricant to the bearings to fix the issue, but the fan could still die in a few years even if it's lubed really well and what really makes me disappointed is that the fan was brand new and cost around $450. This is not something I want to replace again if the brand new fans from the factory have some sort of defect.

Has anyone had similar experiences with brand new interior AC fans and does anyone know about aftermarket upgrades?

There are no aftermarket upgrades.

Get yourself some turbine oil in a squeeze bottle, with a long spout.

Update: I finally got around to removing the fan and inspecting it. The fan spun extremely stiff. I suppose these "new" fans were sitting in the factory for so long that the bearing grease has dried up, or are poorly made. I lubed it up with the "Zoom Spout Oiler" from home depot. It spins clunky, but it turns more easily.  Now I just have to figure out why the fuse keeps getting too hot. I read on here that it was because resistance was building up in the fans, but since both my exterior Condenser fan and interior fan are new (and re-lubed) I didn't think it would still get too hot.  However I have also read that this circuit does get hot regardless and the fuse can shrink, which causes resistance build-up. The fuse is not plastic, but thermo plastic. I can't find ceramics anymore.  eBay advertises Ceramic fuses, but when I bought them they were actually plastic and I had to be refunded.

I have also tried buying the cheaper Bosch motor without the turbines attached, but the shafts were too big for my turbine cages and I had to return that as well.  

Hopefully this information is helpful to someone in the future.