This is killing me slowly since the winter started....

My 03.5 sedan has a rattle in the driver door. Very light taps, especially on the bottom of the window control box where it countours into the door, leave a faint but noticable rattle that returns 3 clicks of sound or more. This is noticeable when driving on colder days and usually can be heard over stereos on 7-8.

Now ~ I have the tweeters from Polk I intalled myself but when the rattle was born I pulled the panel off again and put weather adhesve wherever it was possible to have a wire or crossover touch the door and tied the a mass of wire and teh crossover down tight with a tie. The Polk install is not making noise via wires or crossover banging the metal/plastic in the door. I assure you.

Do you guys think the dealer will balk with the polks? Also will anyone agree that my research is possibly correct in that I think it is a motor attachment or window assembly issue?

The three taps back are interesting.....



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i had a rattle coming from the polk crossover cover. i had pulled the cover off the crossover box exposing the components. i think the cover was vibrating since it's so loosely constructed. i figure the door panel will keep the components protected. it's not like the cover made the box airtight anyway.

 

Great Idea - I'll try that - it sounds like a rule being plucked off the edge of a desk - very quielty and softly

 

that's RULER not RULE : re above

 

I had a door rattle that drove me nuts in the driver door as well. Finally tracked it down. If it only rattles when the window is in full up position and not when it's lowered a bit, then it's your window regulator which needs to be replaced under warranty.

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Maybe your door is haunted? (3 taps back)
Just kidding! :-)

On a serious note, why dont you put the stock speakers back in and tell the dealer to tighten everything. Then you can also show them this service bulletin (see link below). They will take your door apart and put in urethane pads and felt cloth. Guess you could leave your Polks in and try to see if they will do the work anyways.

http://www.nhtsa.dot.gov/TSBScans/sb631189.pdf

I had some rattling too. They tightened everything up on all doors and rattling went away.
Hope this helps.
Good luck