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Not quite done yet but here are pics of my attempt to fix the passenger door rattles. From what I have read on here I'm not the only one suffering from these rattles in the door. I put foam tape in the problem areas that I thought were rattling or might rattle in the future. One of the main rattles that was stereo related was the door panel vibrating against the speaker. That is now fixed. My car has been rattle free up until 10,000 miles or 1 month ago. It now rattles like crazy all the time, stereo on or not, at all speeds, and on any road surface. It drives me nuts. I narrowed it down to the door latch, don't know why it is rattling, but it is and I cannot get at it. I will have to see if the local dealer authorized mechanic can fix it but I know what they are going to say, it will either be "not fixable" or "can't duplicate problem." After putting the door back together I now have another loud rattle when using the stereo, it is the lower right section of the door panel. I will have to pull it off again and put more foam tape there. Thats all for now, I will update in the future with more results.

Foam around speaker area, I highly reccomend this.

Door latch that rattles ALL THE TIME!!!  :x





 

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i have noticed quite a rattle coming from my doors with a considerable amount of bass. payday seems like a good time to try this!
 

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yeah, the Fusion speakers will rattle with the bass kicked up. But I am lazy, so I just turn down the bass. Hopefully the '07 models are much quieter. I have several sources of random rattles and squeaks, but not enough to really bother me. Every once in a while the steering wheel column will give off a styrofoam-against-plastic squeak, and sometimes there is a rattle elsewhere in the cabin but overall it is tighter than most newer cars that I have driven.

[quote author=dtrkted link=topic=58168.msg980993#msg980993 date=1159460424]
i have noticed quite a rattle coming from my doors with a considerable amount of bass. payday seems like a good time to try this!
[/quote]
 

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I may be a little late on this but there is a TSB to fix this problem, im having it done soon. It involves new door panel clips and "flock" tape installed in certain areas around the trim panel.
 

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I have resolved the latch-striker clunking. (when I hit a big bump, you hear this metal to metal clunking/rattling).
Apply white lithium grease to the striker and little bit on the latch and watch the problem disappear. Ford is releasing a new striker which is coated/insulated to prevent this problem....
 
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