So my heater started making an awful noise (loud growling) a few days ago, it also stopped working on any other setting other than high...so I replaced the resistor and when doing that I went ahead and pulled the fan/motor out to find the fan was very wobbly on the motor so I got a new motor and put in. I still had a little bit of a growling noise but pretty quite...Started pickup up this morning and it sounds like hell, could the plastic housing the fan goes into be warped or something?
Also, you can get a leaf on the resistor pack that gets heated by the coils, which can make the leaf smolder...that can make for an unpleasant smell in the cab, and there's even the remote chance of that starting a fire.