Ok update to this mystery.

The problem was not at all with the w210 design or quality of parts. It was a previous mechanics poor workmanship. Whoever replaced the radiator in the past, failed to install 3 of the 4 mounting supports (only had 1 lower frame grommet and zero of two top radiator to bracket clamps). So it was basically floating and could bounce around. I'm guessing someone did infact also hit a parking block or something because the frame mount below the radiator was bent upward. I had to pound out the bends in the sides of the support bracket with a sledge hammer to even get the old radiator out.

So, new fan and new radiator and the mounts to keep it from bouncing around and making contact with the fan and now this should never happen again.

Problem solved!

__________________
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