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The blower fan on my gas furnace sounds like it is hitting other metal when it turns on or off. I had it serviced and he replaced the blower run cap but it has started again after about a week.

Could it be the furnace is not level? The service man said no that wouldn't do it but that's what it sounds like.

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Of course it could be, but probably isn't. A spinning fan will hit anything in its path regardless of the relative direction of gravity.

I'd recommend calling your service person again for further troubleshooting.

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