I took out the blower fan earlier today and didn't find any debris inside it or in the duct area where it sits. However, when I was putting the lower passenger ducting back in, I could hear some sort of plastic/paper sitting up in the area around where this ducting runs. I couldn't see it but I was able to get my arm up there and grab a hold of it which ended up being an approximately 3x1.5 inch label likely for some part. Only half of it was stuck on as the adhesive on the other half wasn't really holding (looks like a bunch of dirt/debris was stuck to the adhesive side). It was near what I think is the air inlet for when recirc is on, so I'm wondering if this clicking sound was this label flapping around and the sound was traveling through the HVAC ducts. Driving too and from dinner tonight I didn't hear the sound at all so I'm hoping this was it.
The blower fan itself was a bit dirty so I carefully rinsed it off and made sure it was completely dry before reassembling everything. The fan itself seemed to spin freely and I couldn't hear any noises when I spun it by hand, so I'm assuming the fan itself is fine. Unfortunately I didn't take any pictures of the process but here's a quick run down for anyone that might run into a similar issue in the future.
1) Remove the lower passenger side footwell trim. It's held in by two screws that use a small hex pattern bit. One of the screws is easily accessible but the other one (closest to the center of the car) is hidden behind the center console trim. I had to remove the side center console trim and the side carpet trim piece (basically the side of the center console in the passenger footwell area), number 6 and 4 in the diagram below. Both of these console trim pieces are just held in by clips so just pull away from the center console and they should unclip. It did take a little bit of force.
2) Loosen the passenger footwell HVAC ducting. It's held in place by two screws as well (phillips) and is attached to the main center HVAC system. It took a bit of force to get it to disconnect from the main center HVAC system ducting. You don't need to take it out completely but you just need it to be loose/move freely in order to get the blower fan out. There is a sensor on top of this ducting so don't try to take it out completely unless you obviously disconnect the sensor (won't be able to see it but you can get your hand up there). This passenger footwell HVAC ducting I'm referring too is circled in red in the picture below. This is a picture of the HVAC assembly as if you were looking at it standing just outside the front passenger door facing the dash.
3) Remove the blower fan. It's held in place by three screws (phillips). One of the screws closest to the front of the vehicle is difficult to get to with a normal size screw driver. You'll need either a really short screw driver or a small ratchet with a philips socket. It also has an electrical connector that you'll see that needs to be disconnected. Removing the blower fan will take a bit of work as the passenger footwell HVAC ducting gets in the way hence the reason it needs to be loosened.
Reassembling everything was straight forward except the passenger footwell HVAC ducting. It's tough to see, but there is a small cut out in one of the brackets underneath the dash that provides line of sight to where the HVAC ducting connects to the main HVAC assembly. Initially, I thought the HVAC duct that I loosened went inside the main HVAC assembly duct, but it actually goes around it. In other words, the duct piece I loosened (circled in red) is the female connection and the ducting that comes out of the main HVAC assembly is the male connection. Once I figured that out, it took some work but I was able to get it back into place.
Anyways, I wish I would have taken some pictures or a short video but hopefully the description above makes some sense. I'll post an update in the near future with whether or not the sound comes back.