rattling sound from driver's door

If you can get it to rattle reliably, take the service adviser for a ride (or let them drive) so they can hear it while you are in the car with them. I'm not a great fan of dealer service departments but sometimes they legitimately can't fix a problem because they can't duplicate it while trouble shooting. If you can demonstrate the problem and show them how to duplicate it, then it's to your advantage.

Be sure they write down the conditions needed to make it rattle so the shop guy can also duplicate it when he is trying to fix it.

 

Gen-II I have a rattle near front door.
It is due to small plastic panel under the small forward window. Never tried to fix it.

 

I call this the "velvet hammer" test. Open your driver's door and make a fist. Now with the part of your fist where your small finger is, tap (as if to hammer) gently over the top curved area of the inner plastic door panel. Move gradually from the rear-most area towards the front. Do you hear a rattle? If so, try tucking gray felt tape between the black rubber seal against the window and where the plastic door panel ends. I had to split the felt in half with a scissors as it was too wide. It will stay in the void without adhesive. If this noise is more of a ticking, it could be the plastics abrading against joined surfaces, but you said it was an actual "rattle".

If you don't get a rattle along the top, repeat the velvet hammer tests along the sides and lower edges of the door panel to see if you can locate a rattle. This could help you when you bring it to the dealer if you can demonstrate it. I had something similar and found foam-tape weather seal worked in some of the voids along the bottom of the door to stop rattles from there. Apparently you've already had the door panel off so you know what I'm referring to. Good luck. BTW, I found this to be a problem with ALL of my doors.

 

On the backside of the inside door panel are small plastic 'pegs' that stick out towards the metal. As said above tap gently around the outer perimeter of the door, expecially near the slot where you can pull the panel off. Mine had one that was a hair away from the metal, and when the panel was tapped(or bumps hit), it hit the metal. A felt sticky underneath fixed it, only 1/2" from edge of panel.

 

I had a similar noise but it came from the back door. Idid take the tech on a test ride twice and he heard it both times. He fixed it the first time and it came back. He fixed it again and now its back again. He said it was 2 metal clips that come loose. He replaced them twice. I have no idea what he will do the next time.

For the record, the Prius is a rattle trap. But my dealer is slowly but surely getting them out.

 

Kempos, welcome to the "rattle chasers club"! I had that noise too did several tests to figure it out. So you've already driven your car with the panel off. You may have noticed the plastic barrier is put on with black goop. Be careful if you decide to peal that back as the stuff gets everywhere and can stain.

Have you heard the noise and then moved around the loose door latch release and lock assembly which is on 2 cables? If you can change or stop the rattle, then you have identified the source. If you can't modify or eliminate the noise after that process, it is most likely something else. But if you can stop the noise by doing that, what I did was use duck tape and taped the cables to a structural area between the upper and lower "openings" inside the door frame. Then I replaced the plastic film. I needed to open the slit a bit more by cutting the plastic to allow the latch assembly to pass thru it, if I recall.

If this is not the source of your noise, could it be something left inside the bottom of the door during assembly? Are you sure it's not in the "B" pillar where the seat belt retractor is located? Have you ruled out the overhead assist handles both front and rear? Good luck - I feel your pain and disappointment.

 

By removing the membrane, you should not void any warranties. If you are careful, it can be re-attached with the same goop but be careful as it can stain and it will get on your hands.

Have you tried spraying a silicon lubricant into the latch mechanism from outside the door? Also, spray some lubricant on the silver latch loop on the "B" pillar to make sure something isn't rubbing to make a noise.

 

I am wondering whether you've been able to take care of the window door rattle in your Prius? I have a 2011 Prius with a rattle similar to what you've described: a "loose screw" rattle sound in the door when the windows is fully up, but completely quiet with the windows even just a smidge lowered.


Thanks