My Fiesta ZXI did start rattling a couple of months back. The rattling was heard somewhere from front left side door trim.
Rattling is really a pain to have. I have had enough since I could not identify the source because I'm the one behind the wheels all the time. Everyone in my family and a lot of my friends really had a tough time with me. Whoever sits in the front seat will be asked to identify the source. Despite all the gimmicks, the source remained unidentified. The only major problem for the loss of clue is that this rattling occurs only on uneven roads, need not be pot-hole-type roads but even roads with little uneven tarmac raised this noise. Hence, this was not present all the time.
Most times, my fellow passengers would never hear the sound. While on the other end, it kills me because the rattling noise kills enjoying the motor of the Drivers Car! Goddamn noise! The most learned technician in Service Station told me to ignore the noise and pump up the volume of the music when i gave it for service last month. That was a logical and wise option too! Plastics, period! But I guess only you guys can understand the experience of driving that was being compromised because of this noise and that too in a Fiesta!
Well, the car has done 55k, 4 years up and this noise was not letting me go!
So last Sunday I pitched in. Driving the car to find the rattling is not a good idea. So I wanted to identify some other way to identify the source of noise. Tried knocking the near A pillar which was most suspected one. Yes, the noise was there. Looked like it came from within the tweeter housing.
Could be some loose wires or some loose holders? But that won't break off so easily! But that's where it comes from and almost concluded it's better not to remove the housing creating a couple of other rattlings in the pursuit of fixing this! Worried and as a last try knocked once more
Accidentally I discovered when hitting the tweeter assembly housing with my hands holding the outer part of the door, noise was gone! Oops, tried again: applied some pressure on the outer side of the door right behind the tweeter housing and "knock knock" .. woohoo.. no more rattling. That's when the bulb started glowing. The rattling is not from inside the housing but the housing itself on the outside where it comes in contact with the door metal.
Take a look at this picture; the driver side A trim tweeter housing.
Neat! The plastic housing is fixed to the door trim and is rock solid and doesn't create any vibrations though it comes in contact with the door metal.
But, this was not the case with the Left side. For some reasons which God only knows, there was a good gap developed between the door trim and the plastic housing. So the source of rattle? As the vehicle moves through uneven roads, the vibrations are carried through the body, the door and reaches the housing. If firmly fixed, the housing tends to dampen them but since it was loose here, they started vibrating with each other. THAT vibration creeps into the cabin via tweeter assembly housing and spoils my driving experience.
Fix? What else could it be other than closing the gap? Tapes won't be a right option because inserting them between the trims is a pain. The other idea i could think of is "Take the 5 rubbes - Quick fix" Applied a nice layer of quick fix between the two trims and NOW, rattling is gone and my driving pleasure is BACK!!
(Here's a pic with quick fix - Doesn't look as ugly as seen here. I have taken the pic at a specific angle with flash so that it will be visible. But hey, it is not so clean. If you look closely at it, you can easily understand the it's jugaad. A week post this fix and No one has identified this yet
. If someone asks me about this after noticing or if it is so worse I'm thinking of getting a Carbon Fiber sheet and sticking it on both mirror housings)