A few weeks ago, there was a sound like a loose plastic something flying around the blower motor. It went away after a few seconds but didn't sound good. The air was still blowing. Yesterday, a low howling sound was coming from the blower and got louder the fast the fan was spinning. I turned the fan off and as it stopped completely, I hear something rattling as if a plastic piece was falling/settling down. The blower is now quiet and air is still flowing.

What could it be? I'm bringing it into service next week for them to take a look.

 

My 2010 Clubman S does the same thing.
The fan makes a noise only when the fan is on the first or second speed setting. Its done it since day one.

 

quite possibly something has found its way down the vent and into the fan box. I've had a small leaf or twig find its way in a time or two, and usually finds its way out again soon. But it can make a racket until it does come out. I just run the fan on high until it works its way out ...

Watch for stuff collecting in the cowl area, especially if you park under trees.

 

Keep in mind that to get to the blower motor they have to dissect your MINI dash. No problem if it's covered under warranty but if they find external debris in the blower you will have to pay some big $$.

 

My clubman is under warranty. If they find nothing or debris, would I have to pay for the investigative work? It was was just something loose flying around, I wouldn't be bringing it in. But there was a loud howling sound that seems to indicate something else is up...

 

I heard the same plastic snap sound and then the howl started in my R53. My howl does not go away. I think I cracked a fanblade or something and now it's spinning off-balance.

 

For the R56 07 MCS the fan drops out past the brake pedal. Pull the knee bolster/cover off the dash below the steering wheel then calypso under the dash and look up. You might find you are looking at the fan motor. Not an hour total to pull and reinstall.

Have not seen a countryman yet but experience has been they tend to repeat things cause it's cheaper than engineering a whole new way to install the fan.

I have a full write up posted here under another thread for doing the R56 fan. Mine developed a whine - very low but got worse the longer it ran, pulled it and oiled the bearings. Been a while now with no noise at all.

 

Got my car back from the dealer shop. As I had feared, since they couldn't hear the howling noise or something rattling around, they didn't even check the blower. The fan blows well even now so I'm not too concerned. At least I have it documented now in the event it fails past my warranty period. May give me ammo to get it replaced.

They did add some padding to some hose somewhere (LOL) to dampen any vibrations that have been reported by others according to a service bulletin.