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The right fan was very noisy above ~4500rpm and I figured it was dirt or then fan was broken (bearings??).
Replaced the fan with a new one from iFixit today and... STILL noisy above 4500rpm.
Any thoughts on why it might still be noisy? (I'm talking airplane take-off noisy.)
My guesses so far are:
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I've usually found that replacing one fan won't work. I've had to replace both several times. The bearing going make a very loud screeching noise along with high RPMs sound. If you did not reset the SMC after replacing the fan please do so. Here's how: http://support.apple.com/kb/ht3964
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If the right fan is revving up and left one not it points to a faulty or not properly connected right thermal sensor. It is located right under the fan.
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Sorry, I guess my original description wasn't very clear. The left fan also revs up but is pretty quiet - audible but not irritating at all. The right fan sounds like an aircraft taking off! Still not sure why a brand new fan sounds just as bad as my original.
Thanks for taking the time to answer though.
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