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Noise / Rattle - Driver side - help needed

Birdmaster

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Thanks for your ideas. i am currently at work. On vacation next week. Mustang (named "Lea") is at home, door panel driver side off. Looking in the evening for more parts which are rattling and making freaky noises.

It is great to know we are looking together to make our Mustang quieter ;-)

Good morning from Germany :cool:
 

StangTime

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Another thing I found that I forgot to mention... when you have the door panel off. Flip it over and inspect all those heat staked melted plastic rivets. I found a few around the armrest area (where your elbow would rest) that rattled when I tapped the panel. Both door panels had this problem. There was not enough compression between the parts when they melted them over leaving a gap. So, I injected some hot melt under the rivet head to fill the gap and make it solid. I also added some hot melt to the plastic tabs which fasten the arm rest pad to the door. They seemed like a source of noise as well.
door panel.jpg
 

Elp_jc

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Flip it over and inspect all those heat staked melted plastic rivets.
Good tip; thanks. Hey, just to be 100% sure, just TWO screws to remove (at the bottom) on the entire door panel, correct? There're typically screws at the armrest and door pull areas, so want to make damn sure how many screws total, to avoid breaking anything if I end up having to remove those suckers (most likely). Thank you.
 

wilkinda65

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Another thing I found that I forgot to mention... when you have the door panel off. Flip it over and inspect all those heat staked melted plastic rivets. I found a few around the armrest area (where your elbow would rest) that rattled when I tapped the panel. Both door panels had this problem. There was not enough compression between the parts when they melted them over leaving a gap. So, I injected some hot melt under the rivet head to fill the gap and make it solid. I also added some hot melt to the plastic tabs which fasten the arm rest pad to the door. They seemed like a source of noise as well.
door panel.jpg
I just got back from the Ford dealer. My 2020 Shelby has THIS exact issue. I have a new complete door panel ordered and coming early next week.
 

StangTime

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Good tip; thanks. Hey, just to be 100% sure, just TWO screws to remove (at the bottom) on the entire door panel, correct? There're typically screws at the armrest and door pull areas, so want to make damn sure how many screws total, to avoid breaking anything if I end up having to remove those suckers (most likely). Thank you.
Yes. Two 8mm screws along the bottom of the door, one 10mm in the armrest and a second 10mm behind the door pull release. Be careful of the seam where the top half of the panel is joined to the bottom half. Don't pull in this area to avoid breaking it.
 

Elp_jc

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So FOUR screws then. That makes more sense; thank you. Will look for a video if I have to do this. With this POS interior, I don't want any more issues with panels. Removing the door pull cover without damage looks challenging. Need to check where is the one for the armrest.
 

Birdmaster

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Yes 4 screws. We did the job a second time without damage.

FYI

 

Birdmaster

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Good morning from Germany.

We are still on our Rattle / Noise Journey... :clap::crackup::lipssealed:

We made a lot of testdrives, 90% noise is located at the top of the driver window.

We pulled out a label on the headliner, but still no chance.

In some youtube videos u see the sideairbag in the roof.
We soon want to take the headliner a bit down on the driver side, if the noise comes from the airbags or its clips...

Thank you,
stay tuned :crazy:
 

geep81

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Good morning from Germany.

We are still on our Rattle / Noise Journey... :clap::crackup::lipssealed:

We made a lot of testdrives, 90% noise is located at the top of the driver window.

We pulled out a label on the headliner, but still no chance.

In some youtube videos u see the sideairbag in the roof.
We soon want to take the headliner a bit down on the driver side, if the noise comes from the airbags or its clips...

Thank you,
stay tuned :crazy:
Please post if you solve it! I also have a small rattle above my head on my 2020 GT.
 

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