Holy Smokes Brian, that is the first I've heard of heat causing the front grill to melt! That is extreme heat for certain. Have you eliminated a failed thermostat, trapped air in the system, proper fill, etc.? I'm not certain, but I think it's possible for the electric fan motor to run in reverse if it's out of phase. Beyond that, I can't elaborate. Too bad you didn't notice the air flow when you opened the hood to check. On another note: I was just there today in Brentwood and got detailed at a place on Balfour! Came home tonight after a stay with the daughter and son-in-law off of Sandcreek. Wish I could be of more help, hope you can figure it out, let us know!