2018 Ford Expedition, Limited Short Wheelbase- Love my truck. One suggestion to Ford Engineers- I have a tendency to rest my left knee against the driver side door panel. Now with hot summer temperatures, (90's), the door panel makes a creaking sound if leaning my knee against the door panel and it does move slightly. Suggest reinforcing the door panel in this area.
I had the exact same issue. I'm a big guy - 6'4" 315 lbs. I picked up my 2018 Expy Limited in mid December. After only a couple weeks, the squeaking in the door panel started. It sounds petty, but imagine picking up your $75,000 truck and listening to a squeaky door panel. I tried like crazy to adjust the way I sit so my leg wouldn't rest on the door panel, but after only a few minutes, my leg went right back there. I took it in for service and was able to replicate the noise. I picked it up, and just a couple days later, the squeak was back.
I pinpointed the noise to the area where two surfaces meet. Unfortunately that area is also a flex point:
Here's how I fixed it:
Push the simulated wood grain area outward and insert a business card
Trace around the arm rest with a pencil and pull the card out
Cut the little piece out but make it a bit smaller than your pencil line so it will not be visible when installed. User a black marker to color the edge of the piece you cut out.
To install it, push the wood grain area again to open up the slot a little. Once you get it started, use a credit card to push it beyond the exposed area.
UPDATE: When I went through this process and took these pictures, pushing the piece beyond the visible area did not eliminate the squeak. I think the trick is to insert the card vertically vs horizontally and make the piece thicker and/or perhaps a little larger. That said, I just jammed another full business card in the same slot. Solved but phugly...
It takes about 10 minutes and saved me another trip to the dealer...
FWIW, I also tried lubricating the gap instead. It was ok at first but the noise came back...
Now I love my new truck...
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