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Thanks. I will be looking forward to the pics. I have been a bit lazy on this as I had a remedy for both symptoms but it would be best to fix it so it works properly.

I should add that my fan engages when I first start the truck below 20°F and will not disengage until it has warmed up some and I shut the truck off and drain the air. Then it works normal, I think. When it's that cold it wouldn't engage anyway. Does anyone else that has the rattle at idle have...

That'll rob some power. I can feel my power reduce when going up hill (especially with a load) when the fan kicks in.

Same here. No room for even a sheet of paper. Very tight. It sounds internal, like a gear or something won't fully engage at idle but does at higher RPMs.

This got me curious (since mine rattles at idle upto 1000 RPMs when it engages) so I checked my bolts and they are studs (A2) and all are tight.

I second that! Mine makes the rattle sound at idle, but if I give it a tad of throttle it goes silent (other than the fan blasting air). Not like it overheats when it rattles, as it still cools, but it seems not quite right.