Dull "rattle" inside driver door

[jdc28va]

2020 Explorer Platinum. I have a dull rattle inside the driver's door, almost like a wire is hitting against something when I go over even slight bumps. It's barely noticeable but it's there. I know if I ask the dealer about it, they'll say they don't hear anything. It also makes a quick rattle noise when I shut the door. Shutting the door sounds more like shutting the door on my dad's old '60 Chevy Impala used to sound versus the crisp solid sound I expect it should make.

Any ideas / recommendations? I almost want to pull the door panel myself to see what's going on, but at the same time, it's under warranty still so I don't want to further mess anything up. I assume it's something simple like a wire harness that came out of a clip. How hard is it to remove the door panel? I removed the panel on my old 2006 Ford Explorer a few times but never this one.

 

[fordsinNC]

Under warranty? Don't touch it - drive it to the service manager and repeat the noise for him/her. Its their dime. You break it, you own it.

 

[themishmosh]

Could be the undershield covering if it's a tapping noise, especially on the highway. The fasteners are really poor and it will flap in the wind and that noise will get transmitted into the cabin. I thought it was the drivers door or B pillar.

 

[J_C]

Door panel can't be hard to remove, going to be same process, remove any plugs and bolts hidden under them, and use a trim tool around the perimeter.

At the same time I agree with fordsinNC, if it's under warranty you should let a dealer shop fix this, but I'm wary of dealer shops, had some !#$% experiences with a few so I'd want to know what is wrong before deciding whether to take it to a shop. Heh, if it's just a clip, or loose rivet or other fastener, it could take less time to DIY fix it than schedule a shop slot, drive there, leave it and drive home, wait, drive back to pick it up.

 

[fordsinNC]

Well, themishmosh brings up an idea - a problem I did resolve myself after some research. Those 3 plastic fasteners under the body in the door area make a lot of racket at highway speeds. Check if the panels under there are loose and then notice the plastic nuts holding them on - they won't tighten but a small amount. Replace them with a metal washer and an M6 nut like all the rest are from factory. Check my previous posts on this - I hope it work out for you. It was a happy day when I discovered this and made the fix.