I’m gonna cry.
The kidney shroud is somehow pushing the fan grille into the new fan. Maybe it’s a shoddy ill-fitting aftermarket part, maybe I just over-tightened the bolts on the shroud. Either way I have to pull the whole thing back apart to try and fix it. Next time I’ll have time for that is at least a week from now. That’s another week of no A/C, and another week of hoping the weather doesn’t get warm enough to make that fan kick on on its own.