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The squirrel-cage fans (one on each side of the motor) are probably okay even though they've been rubbing on the fan housing. Just make sure there isn't extreme abrasion of the edges which would decrease efficiency (when you see how the fans relate to the housing you'll know what I'm describing).
240's require a blower motor specifically for 240's. There are good aftermarket ones available. Be very sure the motor is for your model. I was sold an aftermarket fan for my 1982 240 that was designed for mid-80's cars and had to do some grinding to the innards of the blower housing to obtain a good fit--a tedious pain in the butt.
The Brickboard consensus is to replace the resistor at the same time. In my book, if there is any reasonable chance of resistor failure in the forseeable future, you don't want to repeat this procedure to save $20.
I haven't done the chop-shop replacement, but have been tempted. I seriously considered cutting a hole in the passenger side of the fan housing to remove the clips on the fan for that side only. One could check in advance to find a suitable plastic plug or cover (hardware store) then cut a round hole to match precisely, and it wouldn't be terribly sloppy. All you need to do on the passenger side is remove the flat clip holding the fan to the blower shaft, and then to be able to replace that fan and clip when you install the new motor. The passenger fan wouldn't necessarily even have to come out of the housing. I would still dismantle the driver's side so as not to destroy the venturi baffle on that side.
Fellow Bricksters?
Phillip
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