If its a new problem, probly the switch. Could be water pump start start'n to go bad. What size fan blade? Is it mounted 50/50 into shroud?
Wouldnt worry about x-fillers(upper close out panels) and baffles(rubber seals in front of core support) yet unless your have more then stock power or A/C.
Not to digress...I've seen many cooling system related posts that refer to the fan being 50/50 in/out of the shroud...don't really understand why? Every vehicle I've owned, seen or worked on with a fan clutch type system has had the blade fully inside the shroud. The only thing I come up with is that the clutch thermostat may be too close to the radiator? Maybe just inherent of these first gens?
