Passenger Door Rattle - My Solution
A while back this problem was discussed. There were various solutions. Most just decided to live with it. Nobody seemed to could figure out what exactly was the cause. My temporary solution is shown in Pic 1. It did work. Not to cool, huh?
I decided to go after it. I put fingers on each component I could reach and beat on the door with my other fist and felt out or saw what vibrated. The whole job took a while - about 3-4 hours. '03 Ranger XLT 2-Door.
I found that the relatively heavy window motor is mounted in the middle of the lower section of the door which is a thin metal panel the length of the door. It is mounted with 2-3 bolts/screws/rivets and it vibrated by itself. The thin panel also vibrated by itself. The combination of motor and door panel vibrated as a unit. There was a plastic wire routing gizmo that also rattled.
So that's what the problem is. If the lower door metal panel could be braced or a stiffener maybe welded on that might fixit. I didn't have any way to do that. There's probly better ways or maybe it's too much trouble but here's how I fixt it:
1. I stuck a cut-off piece of radiator hose between the motor and the door panel. Pic 2.
2. I stuck some 1/2 inch thick carpet underlayment foam under the plastic wire router gizmo. Pic 3.
3. I stuck some carpet underlayment foam 1/2 inch thick on the inside of the trim panel. Pic 4.
4. I initially tried to stick some softer thicker 1-1/2 inch thick from a cuttup pillow on the inside of the trim panel but couldn't get the trim panel back on. Had to use thinner stuff. Maybe with help it coulda been did but I didn't have any.
Drove it a couple days over every bump in sight and the rattle has gone away while driving.
If I pound the trim panel low down on the open door with my fist it will rattle like before but not near as bad.