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Noise From Rear Door Panels ST (cracking/popping)

rednax321

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2020 Explorer ST
Build Date 10/19
Purchased 11/19

I’m experiencing a loud popping/cracking noise from the rear driver side door. The noise is observed when traveling over uneven pavement. It sounds as if adhesive is separating and reconnecting. I took the vehicle to a local Ford Service center. Technician there acknowledged the problem and took the panel apart. He said that he didn’t see anything wrong and that similar models also made the noise. If I push on the panel itself near the window, it sounds as if there is a gap where the window sun screen is. Has anybody else experienced this noise or found a way to fix it?

I took the vehicle back to the service center at the dealership where I purchased. There are about 12-15 problems that I’m having (most of which are listed in this forum) and I wanted them addressed. They kept my vehicle for 24 days and a majority of the responses were “unable to be duplicated by service tech”.
 
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themishmosh

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Cheapness begets cheap sounds. The interior is cheap. Most parts are solely fastened by clips. The pieces are cheap plastic with no noise reducing felt tape or anything. I don't want to compare interior quality with another Ford product since this is my first. This car/truck reminds me of my old 2004 Subaru WRX. Above average performance and a utilitarian but cheap interior. Actually, as much as I loved that car, this one trumps it because the driving tech and sound system are very much appreciated.
 

peterk9

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rednax321

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I searched (apparently not hard enough) for a thread about this. Thanks for your help. I’ll do some research.

Wasn’t sure if anybody had a suggestion for something to shim in the door panel, without taking the entire thing apart?
 
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rednax321

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Not sure if anybody else was having this problem? I started taking things apart and realized what the issue was. The foam/rubber on the door is held in place by pink plastic “trim panel retail clip” type of things. When they move, they scrape the panel and make noise. I took the foam/rubber off, cut and slid tiny orings under the gap and used gorilla tape to make the clips immobile. Drastically reduced the noise (from the door panel area). Rubber retaining clips would have also eliminated this problem. Two Ford service centers were unable to determine what the noise was and either said “unable to duplicate” or “characteristic of the vehicle”.

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Vash610

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Not sure if anybody else was having this problem? I started taking things apart and realized what the issue was. The foam/rubber on the door is held in place by pink plastic “trim panel retail clip” type of things. When they move, they scrape the panel and make noise. I took the foam/rubber off, cut and slid tiny orings under the gap and used gorilla tape to make the clips immobile. Drastically reduced the noise (from the door panel area). Rubber retaining clips would have also eliminated this problem. Two Ford service centers were unable to determine what the noise was and either said “unable to duplicate” or “characteristic of the vehicle”.

View attachment 177972

View attachment 177973
Is it easy to take off the door? My speakers rattle and I wanted to take off the door and see if a screw was loose.
 

rednax321

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Is it easy to take off the door? My speakers rattle and I wanted to take off the door and see if a screw was loose.
I didn’t take it completely apart. The rubber strip is held on by tension. I wiggled a couple clips out to see what was going on but that’s as far as I went. Taking that rubber stripping off is very easy, just requires some patience.
 

cbFL

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So I had similar sounds, but it wasn't just the rear door. I would hear it from all doors when driving in the 15 to 45 MPH range, and even louder with a quick turn, or normal braking or anything that would make the body flex. I also noticed if I pushed on any of the doors from the outside they would make a creaking/popping sound from the top. What's strange is it only started a few days ago, and I've had the car since a little before Thanksgiving. I'm in North Florida and it just started getting warm, so the weather might have something to do with it.

Anyway, I was able to fix it by applying some Teflon wax lubricant to the outermost piece of weatherstripping (above the hollow piece that you re-attached). I did this around the top and back sides of all four doors, and it solved it.

Tip: Don't be an idiot like me on the first door and directly spray the Teflon wax; that was fun getting the residue off my window and door. Even if you roll the window down (you know, basic common sense that I lacked in the moment), I would spray it onto a paper towel or rag, getting it wet enough that it will transfer.

The can says o-ring safe, so I'm hoping that means it's good for whatever rubber and plastic material I applied it to.
 
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