I have an early build 05 and I need to find the location of the aforementioned bad welds in the rear of the car. I have a horrible metal on metal rattle in the rear of the car that I cannot track down. The car has been to the dealer on this issue to no avail. If I can determine if I have bad welds I can point them out to the dealer and get them fixed much faster, hopefully fixing my problem.

Has anyone had these fixed? If you did what was their location?

Any info greatly appreciated. Tried searching but could only get a vague idea that there are bad welds.

 

Where are you getting the info that the early build cars came through with bad welds? If it's true I'd like to know about it.

 

There were bad welds (Frame Box) on early 2003 Mustangs, which included Mach1s. Never heard anything about the 2005 having a similar problem!?

 

I had a similar noise on my 05. I just bought the car in October with only 2000 mi. I have already had the driveshaft replaced due to vibrations from 60 to 70 mph. Anyway, to make a long story short, the rattle turned out to be the left hinge on my trunk. I used some silicone spray to lube up the hinge, and the rattle is gone. I’m not sure if there is an underlying problem, but at least that godawful creaking rattle sound is gone. Hope this helps.

P.S This is my first post, and I just wanted to say: WASSSS UUUUP!!!!!

 

I found this info in some of the old "I have a rattle" threads but no one ever mentioned the exact location or even if the problem was widespread. In these threads there was mention of some missing welds on the early 05 builds, Nov and earlier. It was nothing big, a few spot welds in the trunk area that led to metal on metal type of noise. All I know is i have that type of rattle that the dealer has tried to find twice. I will go back again but each time it is a least two hours of my time I would rather do something else with. Not a dig on the dealer, rattles are a PIA to track down and Ford does not keep a database of each one(they should as it would save them money on warranty repairs).

I just wanted to know where and what to look for if anyone has had these fixed or even remembers the discussion.

 

I will look into that, thanks.

 

Also might check your license plate, if it is screwed in with only 2 screws on top it might be rattling. I noticed mine the other day, finally tracked it down to the plate. I could only hear it rattling when the rear seats were folded down though and the radio off. Anyway, good luck!!

 

I had the same problem in my '05. Every bump in the road would produce a rattle sound in the trunk area. I got fed up one day, hopped in the back seat, kept slamming my fist against the rear ledge where the rattle was coming from. I was able to pinpoint the general area and got in the trunk (lol not fun) and banged around in the same area where I found the rattle from the back seat. Found problem area, took a screw driver to bend the place two pieces of metal overlapped and have been problem free ever since. Mine was "born" on April 11th 2005 (lol a MONDAY!!). Obviously robots that do all the welding get tired on Mondays also! haha

 

Tried that and could not find anything...mine seems to be in the body work or frame in the rear. It happens at 1500 rpm..it seems to be based on if the trunk area is cold. This is what makes it hard to track down.

 

Ford's robots take holidays as well (ERL is not an exception).

 

You're not crazy - I am pretty sure I remember that bad weld thread - it had photos.

But I believe it was from the time period prior to the forum changeover, so it is not likely to have survived until now.

 

Jon is correct there was a bad welds thread a long time ago and it had to do with the early run of the 2005 .I'm not positive but I think it was from sept. to mid oct. build time period .I belive it had to do with the rear quarter panel and the back deck where the speakers are attached (rear quarter to deck)some where in around there.I belive a T.S.B. put out about this so check in the forums and see if it's there and if your car fits in this time period.

 

I've got a rattle in the left rear trunk area also. It sounds like it is coming from the rear quarter area around the gas filler. My son & I took turn riding in the back with the seats down and into the trunk. Sound is upon heavy exceleration and cruise speed of 1800 rpm's. It;s odd but it does NOT do it on every road but will on the same road in the same direction each time.
I have taped with sound deading material around the gas filler tubes in the wheel well, the fuel line underneath and a wire connection but I still have the sound.

 

Did you have the fuel tank TSB?

My rattle occurs at 1500-1800 rpm. Come to think of it I did not notice it until after I had the fuel tank replaced...and the fuel filler neck seems to move.

I checked the TSB's there is a TSB on welds but not their location.