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Sounds like I have Godzilla in my car,
horrible noise when I operate my a/c ,Is this from my blower outside the firewall pass side? or is ther something under the dash that will make my life miserable thats making this noise..having to turn a/c on and off to get it to stop, but is now getting more frequent..
Some debris from the window vent maybe be getting caught up inside the squirrel fan cage or the motor is shot. You will need to remove the blower motor. Somewhat easy to get to and I suggest pulling the passenger front wheel off and the inner fender for clearance. The motor is about $35-$50 to replace with or without the squirrel cage. I suggest pulling it, vaccuming out the blower suitcase and installing a new blower motor.