I'm just about tearing out my hair.

Here's the deal. My wife said her E300 wasn't right. I discovered that the fan had flexed a blade forward, grabbed the shroud, and put a hole in the aluminum part of the tank flange in the radiator. Grrr. So, I disassembled it all, put in a new fan, shroud, and repaired the radiator. I noticed that it was still contacting the shroud and radiator. In desperation, I disassembled again and rotated the rubber lower grommets 180 degrees which got me another 1/8". Then I reached under, grabbed the lower radiator support and bent the sheet metal forward about 1/2". So, now I thought it was OK and I only spent one day and $130 in parts.

But today the same !*&^$^& thing happened.

Is this a common problem? Is there a fix? I'm tired of tearing it apart and I can only patch the aluminum so many times. No matter how I assemble it I can't get enough space between the radiator and the fan.