Tacholio’s that danged door rattle fix thread

A short DIY for those suffering the same...

Model : 2013 Access Cab TRD Sport with 21K miles

Symptoms :

• Bass speaker frequency induced rattle coming from driver’s side door (stock audio system)
• Rattle present even with middle settings on equalizer and normal / reasonable volume
  
• Symptoms not present when new, progressively worse with time (to the point of frequent aggravation)
  
• I could lessen the rattle if I pressed down on the black trim panel that holds the lock and window switches
  
• So far only the driver’s side door has had the problem, passenger side door has yet to have the issue
  

Fix Attempt Part I :

• With the interior door trim panel off the door frame (but wire harness still plugged in to lock/window switch unit) and music playing it seemed like there were two sources of noise:
• • Moisture barrier plastic sheet was vibrating
    
    
  • Could feel a buzz in the wire harness to the switch unit and in the switch assembly trim panel
    
• To try and calm down the plastic sheet I attempted to dampen it out / change its frequency range. Using black Gorilla brand tape and cuts I made in the plastic I would apply the tape to the sheet on one side of the cut, the thread the remaining length(s) of tape through the cut and stick it on a structural part of the door (being sure to avoid any functional parts related to window track, etc.). This acted to tighten up the sheet. I then re-sealed over the cuts with tape.

• To try and address the wire harness I used tape to try and firm up / stiffen its attachment to the door (I did not see a practical way to isolate the harness from the door frame which fundamentally would be the other direction to take when addressing a noise source.)
  
  
• Result: Only partial improvement. But it seemed like I could now eliminate the rattle if I firmly pressed down on the black trim panel that holds the lock and window switches
  

Fix Attempt Part II :

• At this point I had some DynaMat so I put it to use. I added pieces to some areas of the moisture barrier and to the switch wire harness (to try and dampen them out). I removed the bass speaker and trimmed out its mounting surface (to try and isolate its input to the door.)
  
  
• Additionally I contrived a way to tighten down the switch and trim plate assembly, which was a bit loose to the touch even with the black mounting trim piece snapped in place to the door. To do this I drilled a small hole in a structural piece of the door trim panel to act as an anchor point. I then used a zip tie to go around the switch assembly and through the anchor hole. This realty tightened up the switch panel to door panel connection.
  
  
• Result: Success ! No more door rattle !!

 

I've got it too. Had it on my 2010 and I fixed it by taking the window control panel off and stuffing regular old house insulation into the hole. Good idea though. I've got to fix mine in the near future.