'04 - Squeaks & Rattles - Long

[rainmn]

I'll start by apologizing if this turns into a rant...this truck is really starting to get on my nerves. It's an '04 w/ about 6K on it now, 6 months old.
This thing seems to develop a new squeak, rattle, or otherwise annoying noise everyday. Oddly enough, this is one of the reasons I didn't buy a Suburban or a Yukon. Every GM I've had any experience with at all has always turned into a rattle trap, which is a major pet peeve of mine.
My '00 Excursion was still pretty solid the day I traded it in. Again, adding to the reason I stuck with a Ford. (I'm starting to regret not getting the Seqouia or the Armada.)
Anyone else having these problems with a new body style? The colder out it gets, the worse the truck gets. The driver's door squeaks against the weatherstipping non-stop. One of the rear doors is starting to follow suit. The passenger airbag makes a horrible squeak against the dash over the slightest bump. Something in the cargo area is just starting to make noise that I haven't even tried to isolate yet. Let's not even talk about wind noise.
I'm bringing it into the dealer, yet again, but don't hold much hope for the morons. This will be the 5th trip to the dealer in 6 months now...a new record for any vehicle I've ever owned. Last time there, I only mentioned the driver's door squeak. They said they "Cleaned" the weatherstrip, as it might have had wax on it. I'm 100% positive now that they just wiped it with silicone, since the squeaking only stopped until the first rain.
Between these noises, the truck dying in traffic at 2 weeks old, and the driver's leather seat cover wearing out after 5 months and 5K miles, this thing has really got me annoyed. Every time it goes to the dealer, there's someone else there dropping off an '03 or '04 Expedition for the same crap as me. Last time it was the wear on the seat...the other person's truck was 1 month old.

Yep, it turned into a rant. Sorry about that.

 

[ExpyBob]

Join the club. Mine as noises too, in the drivers door. I lube with silicon and it lasts for 4 months or so. This shouldn't be.

My 2000 Expy was quiet the day I traded it at 76000 miles.

Bob

 

[blkexp]

I feel your pain, I have an 03 and the rattles just keep on coming. If you find out how to solve the air bag rattle please send a thread.

 

[rainmn]

Update on the rattletrap..it just went to the dealer today.
Passenger airbag squeaks - supposedly missing clips from the factory.
Driver's door squeak / rattle - supposedly adjusted, advised by Ford of a different type of gunk to put on it. Great solution...now I have slimy weatherstripping. Service Mgr. doesn't seem to have much hope for this "Solution," since he's already talking about what to do next.
Not mentioned in my original post was a belt squeal that recently started. Turned out there is a TSB on this, which required them to order an updated belt and pulley, which will take close to a month to get.
More fun....

 

[hmatthews]

squeeks and rattles

I feel your pain! I bought my 04' exp new off the dealers lot about 3 months ago. I have bad tires...within 5 days the vehichle began shaking and rattling - I have had it into the dealer now 3 times and a tire discounter's twice. Now that the vehichle has been shaken out of alignment and is absolutely miserable to ride in... i cant get any one of 3 dealer warranty people to call me back! And my family all works for FORD! Go figure! When i purchased the vehichle i assumed a $40 thousand dollar car would ride/handle better than uncle bob's 1977 chevy pickup! I am frustrated as all get up. These people have about 10 days to make this right or i will park it right back in their showroom! i have never had such problems. The noise from the air alone coupled with the nobby warped tires... i have just about had it! I am about to make my 2nd of 60 payments on this thing... sad.

 

[soneill]

I am also an unhappy member of this not distinguished club. I have on 03 EB and this thing sounds more like a rattletrap the the fishing lures I use in the chesapeake bay. I have had so many problems (to long to list), but, have solved all but the fact that the car rattles beyond belief. I wanted to trade it in, but, I have all the bells and whistles needed for any suv, so, I guess I would be better of getting xm radio and some very loud speakers installed to keep my sanity. The price that they are asking for new and used vehicles just makes you want to get sick. This, at some point in time will be my last ford. Sad to say, but, true.

Soneill

 

[danketchpel]

I also dislike the various rattles etc. Coming from a Toyota truck that had almost zero interior noises (after 180,000 miles) when I sold it seems ridiculous. We still have a Camry with 177,000 miles on it that's much quieter.

My main peeve is the creaking noise from the drivers and front passengers windows. I HATE it because it's right in your ear. Even my wife as commented on it and she is extremely tolerant of interior noises.

Her comment was "it sure doesn't sound like a vehicle that's less than a year old".

Does anybody have any fixes for the window creaking noise?

I'm planning on taking it to the dealer to have it fixed but I would like to know if there are any proven cures.

 

[rainmn]

Are you sure it's the window creaking, and not the door itself against the weatherseal? The latter is the problem I have. (And both of my friends with the same truck also have.)
Easy to check - wipe down the weatherstripping with some sort of silicone. If you have the same issue I do, the noise will stop until either it rains or you wash the truck.

BTW - my wife is also pretty much oblivious to rattles and squeaks, but she even thinks this truck is a POS.

 

[danketchpel]

I have wiped down the rubber door seals with dow corning dielectric silicone grease which helped the other softer sound of the door against the rubber and didn't last very long.

What I hear is a fairly sharp "cracking" type of sound that sounds like it's coming from between the window track and the door frame. If I push on the window (closed position) with the door open I can make a similar sound but can't find exactly where it comes from. It might be from someplace down inside the door where the track mounts to the door frame.

The sound does get worse after a rain or driving longer distances (more rubbing). Also it's worse when towing due to more body flexing. I took my cousin dirt biking a couple of weekends ago and it was really bad.

 

[hmatthews]

Maybe this is more of a suggestion than anything... i have the 04 (bought in jan 05) and have had terrible rattling /shaking... i have been pressing my dealer to handle it. Now after, the 5th time of being dropped off the the dealer they aggreed to reimburse me for the purchase of a new set of tires. apparently the continentals' on these expy's are junk. so... they did. it has helped the vibration and jerky driving tremendously (so far.. tires been on 3 days now and its not as smooth as it was initially but i am gonna give it a couple weeks) It did help the interior noise. If the rough ride returns its getting lemon'd!

 

[jheller]

door rattle TSB needed

Since the door rattle problem obvious affects many owners, myself included, there should be a TSB on it.

Does anyone know the exact TSB# related to the fix and where I can get a full copy to take to the dealer.

I've had it in twice for the problem and they claim they don't hear it.

 

[ExpyBob]

Body - Rubbing/Ticking Noise From Doors

TSB 05-7-1

04/18/05

RATTLE/RUBBING/TICKING NOISE FROM DOORS

FORD:
2003-2005 Expedition

LINCOLN:
2003-2005 Navigator

ISSUE
Some 2003-2005 Expedition/Navigator vehicles may exhibit a rattle/rubbing/ticking noise from one or more doors. This may be due to movement of door relative to the latch striker plate.

ACTION
Drive vehicle and manually pull door inboard while noise is present. If the noise decreases, repair per the following Service Procedure and vehicle build date information.

SERVICE PROCEDURE

NOTE PERFORM THESE REPAIRS ON THE AFFECTED DOOR ONLY.

NOTE CHECK VEHICLE'S FULL WARRANTY HISTORY IN OASIS. IF ANY DOORS WERE PREVIOUSLY REPAIRED USING SSM 17734, DO NOT REPLACE LATCH(S) OR DOOR OPENING WEATHERSTRIP(S) WITH THE PART NUMBERS LISTED IN THIS TSB. IT WILL ONLY BE NECESSARY TO INSTALL AND/OR TUCK IN THE REVISED SHEDLIP WEATHERSTRIP(S).

NOTE DO NOT RESET/ADJUST DOORS IF DOOR CLOSING EFFORTS INCREASE AFTER NEW PARTS ARE INSTALLED. DOOR CLOSING EFFORTS WILL DECREASE AS NEW WEATHERSTRIPS AGE, TYPICALLY WITHIN A FEW WEEKS.

VEHICLES BUILT BEFORE 5/12/03:

^ Replace door opening weatherstrip. Part Number 3L1Z-7820708-BA (R or L Front), 3L1Z-78253A10-BA (R or L Rear).

^ Replace shedlip with new bubble type shedlip weatherstrip(s). Part Number 4L1Z-7851222-AB (RF) and 4L1Z-7851223-AB (LF).


^ Tuck the shedlip weatherstrip under the windshield side molding (along A-pillar), using a nylon blade (Figure 1).

^ Replace latch(s) with revised part. Part Number 4L1Z-78219A64-AB (RF), 4L1Z-78264A00-AB (RR), 4L1Z-78219A65-AB (LF), 4L1Z-78264A01-AB (LR).


VEHICLES BUILT 5/13/2003 THROUGH 7/21/03:

^ Replace shedlip with new bubble type shedlip weatherstrip(s). Part Number 4L1Z-7851222-AB (RF) and 4L1Z-7851223-AB (LF).

^ Tuck the shedlip weatherstrip under the windshield side molding (along A-pillar), using a nylon blade (Figure 1).

^ Replace latch(s) with revised part. Part Number 4L1Z-78219A64-AB (RF) 4L1Z-78264A00-AB (RR), 4L1Z-78219A65-AB (LF), 4L1Z-78264A01-AB (LR).


VEHICLES BUILT 7/22/2003 THROUGH 6/23/2004:

^ Replace shedlip with new bubble type shedlip weatherstrip(s). Part Number 4L1Z-7851222-AB (RF) and 4L1Z-7851223-AB (LF).

^ Tuck the shedlip weatherstrip under the windshield side molding (along A-pillar), using a nylon blade (Figure 1).


VEHICLES BUILT AFTER 6/23/04:

^ Tuck the existing shedlip weatherstrip under the windshield side molding (along A-pillar), using a nylon blade (Figure 1).


Parts Block

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

DEALER CODING
CONDITION
BASIC PART NO. CODE
7851222 41

 

[danketchpel]

A follow up on my "window creaking" issue.

On my first visit to the dealer regarding this issue they replaced the "window runs", not sure exactly which part he refered to. I need to see if the part number is on the receipt. Result = no improvement.

On my second visit,
I took a printout of the TSB listed above to my dealer. They told me that they had done the material replacement but that the doors were not adjusted correctly. They tightend up the fit by moving the striker plate in and that fixed the problem, well mostly. At least it pointed my in the right direction.

I actually readjusted them myself after I got it home because the drivers side was too tight (had to really slam the door) and the passenger side wasn't tight enough (could still hear some noise). I loosened the drivers door and tightened the passenger door and now all is well. Decent closing and no more creaking noise.