Anyone know the fix for the front passenger door rattle? It seems related to the handle linkage because it will temporarily stop if I apply pressure to the handle like I am going to open the door. I am ready to remove the interior panel and start looking. Anyone know the source? What about the exterior cladding? I have heard that it rattles, but I don't understand how.

Thanks,
Tom

2003 EB Expy 4X2 5.4L

 

Nobody else has a door rattle? Come on, I have read numerous posts on this. What is Ford doing to fix the rattle? I am not leaving the Expy at the dealer for a day so they can tell me they don't hear anything. What is the fix?

Later,

 

I have it but my dealer must of been deaf not to hear the problem. There is either a SSM or TSB about the body cladding problem, so they should know how to fix it.

I believe the solution is to add more double stick tape.

 

2000F2504X4 hey guy i have found what may be the answer to
this question i have a 98 eddie bauer expy & i took my expy to an
old high school buddy who has a body shop & asked him what that might be & we drove over the spot that causes the door to be noisy & his response was is that all & i said well yes we went back to his shop & it took him about 30 minutes to adjust the strike plate & we used a larger gromett just to the right of the strike plate this one was a f150 gromett & it has not happened yet & i have driven 3k miles since the adjustment. You may want to find a good body shop & see if that is the same thing on yours.
turbo ted

 

Greetings all. . .

Mine is worst in the colder weather and at interstate speeds - sounds like the glass is rubbing on something. I had a 97 before this 03-EB and it was so solid.

I have been driving the interstate in high winds and my passenger was startled by what seemed like the door being loose and allowing the wind to whip it.

I've had it to the dealer 2 times - the first time they forgot to look at the problem and the 2nd time they looked at me rather blankly since I couldn't make it happen in a ride around the block. anyway - I have also been tempted to rip the door apart . . .

 

Mine is in the shop right now for this. they ordered a new handle latch, saying that is the problem. we will see.

 

I have the same problem on my 04 Expy, window rattle and loud wind noise, it's on drivers side. I haven't rode shotgun yet on the passenger side. So I don't know if it's on that side also. It's been in twice and not fixed yet. But Daveplot mentioned of the door latch and window seal in another thread. And will make them aware of this.

 

There is a new bulletin I was told on this, to adjust the strike plate. It did reduce the level of the noise, but I still have the noise. It may just need to be adjusted further.

 

Here is a SSM that was used for my rattle...

There is also a TSB about the problem. (#03-23-03 -- 2003 EXPEDITION/NAVIGATOR: BODY - TRIM -
NOISE FROM DOOR CLADDING)

17078 2003 EXPEDITION/NAVIGATOR - RATTLE, RUBBING OR
TICKING NOISE FROM DOOR
SOME 2003 EXPEDITIONS/NAVIGATORS BUILT BEFORE 7/21/03
MAY EXHIBIT A RATTLE, RUBBING OR TICKING NOISE FROM
ONE OR MORE DOORS DUE TO EXCESS MOVEMENT OF THE DOOR
RELATIVE TO THE LATCH STRIKER PLATE. TO VERIFY, DRIVE
VEHICLE AND MANUALLY PULL DOOR INBOARD WHILE NOISE IS
PRESENT. IF NOISE IS UNCHANGED, CLADDING RATTLE IS A
MORE LIKELY CAUSE. IF NOISE DECREASES, REPLACE
WEATHER- STRIP AND/OR DOOR LATCH ONLY ON THE AFFECTED
DOOR(S) AS NEEDED BASED ON BUILD DATE: UNITS BLT AFTER
05/12/03 CONTAIN REVISED WEATHERSTRIP; UNITS BLT AFTER
7/21/03 CONTAIN REVISED LATCHES. DO 'NOT' RESET DOORS
- DOOR CLOSING EFFORTS WILL DECREASE IN 2 WEEKS AS
SEALS AGE. WEATHERSTRIP: 3L1Z-7820708-BA (FRONT); 3L1Z-78253A10-BA (REAR). DOOR LATCH: 4L1Z-78219A64-AA(RT FNT), 4L1Z- 78219A65-AA(LEFT FNT), 4L1Z-78264A00-AA(RT RR), 4L1Z-78264A01-AA(LEFT RR)

 

You previously mentioned the SSM that was used for your rattle on your Expedition. Did that SSM fix your rattle completely? My Expedition was built in May of '02 and both of my front doors rattle, mainly over bumps, but it does sound as if the door is coming unsealed and is moving somewhat. So I gather, from your post, that I will need new seals as well as new latches. But before I take mine in for that, I would like to know if these fixes actually fixed your rattle or did it make it worse.

 

They only moved the strike plate. It fixed about 85% of the rattle, so it is MUCH better. I am thinking they might need to put additional/larger seals to finish it, but have not made it back in to have them look at it again. I am focused on the tires issue right now, fighting a severly uphill battle.

 

Khelms,

The parts are on order now. Hopefully before the end of next week I'll have them on.

 

Try this test, roll down affected window 1/2 way on both bumpy road and highway and you'll notice alot of vibration or wobble in the window. The window might be loose as it was on my 03' expy

 

I'm bringing in mine for the window rattle in about 10 minutes from now, I'll mention all the above SSM's etc... I've already contacted Ford Customer Care and they said they'll send a letter to my dealer. This will be the third visit for this problem, isn't there some law or something where if it doesn't get fixed in three tries something legal can be done?

 

4x4...Check your state's Lemon Law.