[Ray 911s]

If the bolts are not tightened evenly the fan will rub in the housing. Generally if they are all torqued to the same value, the fan should sit concentricaly inside the housing. If not, just observe where the blades hit the housing and tighten or loosen the nuts on the opposite side to sqaure up the assembly.

The two fins, in my experience, are easily cracked and nearly every one I've seen (OK, I've only done six of them!) has some small amount of cracking or flexing. They're not under any stress in application, so I wouldn't worry unless it looks like they are about to detach. The orientation of the fins should be twelve o'clock and ten-thirty. In other words, they are not both on top, but are more leaning toward the driver's side. The ground strap, or wire depending on year and previous work, may be causing the interference in the fit.

Also, make certain that the wiring harness is not binding. When you removed the alternator you may have pulled excess wire into the cavity in the shroud. There is enough slack that you could conceivably pull and extra couple of inches inside and that would be sufficient to make reinsertion a real problem. The wires slide through a grommet in the shroud. It's not easy, but you may be able to either push from inside the shroud or pull from outside the shroud to get rid of the slack.

Those are the only potential troubles that come to mind from my meager experience with these devils. I hope it helps. Other more experienced wrenches will certainly chime in as well.