Any suggestions a leaf maybe?? or worn out??? Is it a big job to pull it out and apart to get the leaf out or fix it??? IT's driving me nuts

Internal fan. as in the fan for the heater/aircon?

Just crank it up to top speed, bits of leaf will come flying out eventually. lol Never fails.

lol i live in queensland so has been on high speed for the last three summers it's just pissing me off now days

There are only 3 screws holding it in. Passenger side, under the dash, remove the cover, unplug the wire, undo 3 screws and it will drop out. If its bearings replace it, if its blocked clean it.