It was the upper blend door actuator behind the radio. Clicking noise every time I started it. I did not notice a change in the fan. I took the old one apart and found teeth gone on one of the plastic gears. 25$ at the dealer but i read it can be found cheaper.
blend door actuator
This thread was great. Had my truck a month and the noise started yesterday.
After reading this tread and watching the videos, got the part and fixed it in about an hour. thanks to everyone.
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