blueoval28

Two small screws on the bottom. Top piece of trim comes off along side window. It just pulls off and there is another screw behind it. Now you are down to two bolts. One behind the handle. Use a small flat head screw driver to pop the small black piece out. Bolt is behind it. The last screw is down in the armrest hole. Spot you put your fingers in to close the door. There is a small square plastic piece that pops out. The last bolt is behind it. Panel is loose just lift up and out. Then you can unplug the power window strip and the door opening handle will pop out as well. Hope that helps some.

sky027

I've finally solved this problem, because these new doors made a lot of noise. I was pretty disappointed with the build quality compared to my 97 F150 that had no rattles at all until after 300K.

So anyway, I tried all the fixes such as taping things behind the panel, installing felt pads and so on, but within days noises would be back.

The fix may seem drastic, but it works very well: expandable foam. There are different types, and I chose the one that says it stays elastic. If I'd used the type that gets hard and brittle, then over time it would break down with the movement of the truck.

The problem areas are where the plastic panel meets metal, that's what rattles when you close the door. There are too few screws. But what first rattled the most was the insert above the arm rest. If you hold that in over bumps and the noise stops, then first get to the backside of the panel and spray foam into the two holes behind that insert.
After that, I went around all doors--especially around the lower rear doors of my ext cab, with a chisel and pried the panel back enough to spray in the foam. You want to spray in enough that it oozes out, which you can clean up with acetone.

My truck is so very much quieter now. The door design on the ext cab is always going to allow some movement and noise on bigger bumps, but the panels shouldn't make any noise, certainly shouldn't rattle, and now they don't. Note that if all goes well you shouldn't ever have to remove the door panel again. But if you do need it off again, the foam will release. It's not cement.

Additionally, just yesterday I noticed a new noise and found that it's the wide buttons on the armrest rattling. Today I plan to get some dense foam at work, cut into small pieces and shove them down where I can't see them, which should solve that one.

I'll eventually track down and eliminate every unnecessary and preventable noise.

Good luck all!

Chris_Journey