Hi Everyone,

I've been lurking here for a long time and finally have an opportunity to give back.

I drive a 2005 model year GT and, nearly 15 years after the car was manufactured, I got tired of the rattles coming from the all-plastic interior.

I started my diagnosis by downloading the complete Ford workshop manual. This provided me with simple instructions for assembling and disassembling the interior trim pieces. Next, I looked at some relevant TSB's including TSB 07-17-6 (Buzz/rattle from door panel when operating audio system). Without turning a single screw, I was able to remove the window switch bezel by simply pulling it straight off the door and disconnecting the single plug connecting the window switches.




After removing the window switch bezel and separating it into two pieces, I identified loose tolerances between the window switch bezel and the switch module as the source of the rattle. See the attached "before" video for an example.

In the TSB, Ford recommends purchasing Rotunda's Squeak And Rattle Repair Kit Part #164-R4900 and using the foam tape to fill in any gaps and cushion plastic parts that hit against each other. At a shocking price of $138.95 for a box of tape, I quickly looked for alternatives, and found these on Amazon for much less.


The images below show how I applied the flocking tape around the sides of the control module to let it slid silently, and pvc foam tape inside the bezel to eliminate the empty space and fill the loose tolerance.





This completely eliminated one of the loudest rattles in the interior. You can also apply PVC foam tape as outlined in the TSB, but I found the rattle from the window switches was much louder than the rattle from the two pieces of the bezel.

 

Interesting. Good to know, gonna remember that if it shows up! I do have a question though. All this plastic... are the keepers for the switches on the bezel under duress now that you've added that foam pad/shim? Was it difficult to get that switchbox back in?

FWIW, my rattles from speakers were the inner plastic liner and/or the wiring vibrating. Some of the wiring tape had let go too. All that stuff flappin' about I guess. Taped it down/fixed it as needed, and the problems were solved. I also employed a rubber mallet upon the door to induce said vibrations, and 'patched' as needed. Speakers no longer cause rattle! Nothin' to do with my door panel or switches...

Oh, yeah. There *used* to be something way back when, but I solved that. The two removable pieces under the door handle and the door grip? You can use self-stick soft side velcro squares. Just one in the middle of those two panels will get them to shut up. So there is that, but I'd solved it long ago.

Now... about that package tray rear speaker rattle I've gotten... well, had, sort of, since I just faded to front.. I just don't want to tear up the back seat for it, don't really miss those rear speakers...

Overall, though... I have to say that I don't know what happened, but Awesome simply doesn't have any rattles to speak of. Much grateful for that.

/The suspension with those poly/greasable bushings, though...

//Just add grease...

 

Not at all. The tolerances were so loose that the couple thousandths of an inch of thickness added by the flocked / felt tape didn't affect my ability to get the switchbox back in. Furthermore, the keepers were designed in such a way that they can flex pretty far naturally so I'm not worried about it. The pvc foam tape is pretty thick, but it's squishy enough that there isn't enough force pushing back to cause problems. See the attached video for the complete reassembled unit.

 

Thanks for the info! Much appreciated the reply, man!