AC Blower Motor Vibration Noise

I have an AC Blower noise/vibration everytime I start the truck. To make it stop I have to turn the AC Fan to high and then it goes away and I can set it back to low or auto and the noise is not there.

I can make it happen anytime by shutting the fan off and turning it back on or turning the truck on and off.
I took it to the dealer with 110km on it and they agreed it's a bad Blower and swapped it out for me. After the repair when it didn't fix the problem they said maybe I should just drive it for a while and see if it goes away.

I removed the Blower fan myself and ran it outside the dash and there is no noise. I put it back in the dash and the problem returned.

Has anyone else came across this problem? It's really annoying to have to turn the fan to high everytime I use the truck. It's a TRD sport premium in Canada.
Thanks.

 

That’s bizzare, no I haven’t heard of this or dealt with it on mine. Could you take a video of the noise and post it?

 

Could something be caught in there? A dealer dropped a leaf in mine when changing the cabin air filter and it was making atrocious noise

 

My fan has a very slightly louder sound upon startup. It quiets down as soon as the fan changes speed similar to what you described. Mine is so slight I wouldn’t call it anything to report to dealer.