My 420 SEL was in a minor fender bender and the radiator was pushed into the fan which separated the fan clutch enought to push the fan blades back into the pulley belts. I disassembled and used a chisel to effectively move the clutch back together enough for clearance. Is this an OK solution? The fan blade now moves around freely but the flat plate which is on the front of the assembly rubs against the little bumps on the front clutch cover plate when I spin it. I have about 3/8" of clearance between the fan and the pulleys. What should I do ?

I'm not familiar with your particular fan clutch, but I can say in general that you need to replace the clutch assembly. If the fan is still undamaged, which can be hard to tell if it is a metallic fan, but easy if a plastic composite (the plastic composite fans flex and generally return to their original configuaration unless a chunk if broken off) you can keep it and just get the clutch assembly. Having to use a chisel to gain clearance pretty much guarantees, in my opinion, that you need a new fan clutch.

I would suggest a VERY careful inspection of the fan, if it's metal (it probably is). I think it's cast and will not tolerate any bending - look for any indications of cracks. It would be bad for it to come apart while running, particularly if you are under the hood. If it is out of balance from being bent (again, I doubt if it wil bend much) I don't think the clutch will spin it as quickly as it should.

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