I have the TSB printed off at work. Noticed it one day when checking for something on another truck, so I printed it off because my truck has the same rattle. I'll try to bring it home tommorow if I think about it.

 

Well, turns out the Ford site is working tonight so here goes.
FORD: 2004 F-150


ISSUE:
Some 2004 F-150 vehicles may exhibit a rattling and/or squeaking noise coming from the power sliding rear window.

ACTION:
To service, adhere a piece of urethane padding to the bottom of the power sliding rear window. The urethane pad is available in the Rotunda Squeak and Rattle Kit (part #164-R4900). Parts can be ordered at 1-800-ROTUNDA. Refer to the following Service Procedure.

SERVICE PROCEDURE
Remove upper run channel by pulling down and outward from the driver's side of the vehicle (Figure 1, View A). A SMALL PICK OR A PAIR OF NEEDLE NOSE PLIERS MAY BE HELPFUL.
Remove the rear seat back per Section 501-10 of the Workshop Manual.
Remove the rear trim panel per Section 501-01 of the Workshop Manual.
Remove the center child safety seat tether anchor as per Section 501-20A of the Workshop Manual.
Remove the rear center glass by pushing the glass up out of the lower window run (Figure 1, View B), then pulling forward and downward on the bottom of the pane.
Clean the lower corners of the glass with alcohol (OBTAIN LOCALLY).
Cut two (2) pieces of urethane pad (part #164-R4902) 5 mm wide and 25 mm long (0.20" wide and 1" long).
Attach the urethane padding to the bottom of the lower corners of the glass.
NOTE: BEGIN ADHESION OF THE URETHANE PAD EDGE 20 MM (0.75") INBOARD OF THE CORNER ON THE HORIZONTAL EDGE OF GLASS, ENSURING THAT THE CORNER IS WRAPPED IN FELT.



Reinstall the glass in reverse order of removal. ENSURE THAT THE URETHANE PAD DOES NOT ROLL DURING REASSEMBLY.

PART NUMBER PART NAME
164-R4902 Urethane Pad

Picture for TSB:

 

It took me a week to track the rattle to the rear window. I ended up shutting the window on some folded paper so it couldn't move, and bingo... the rattle was gone. I will be taking it in for this TSB asap!

 

Unfortunately, I just found out that my rattle has turned into a leak. It's going in soon as well.

 

I had the same rattle last year. The dealership did the TSB on it and it did not help. They had an engineer from the KC plant come and drive it. They completly removed the rear glass installed a new seal and no problems since.

 

BIgsherm, what was the final fix for the rattle you had?

 

I have the same problem. 04 Fx4 build date 02/04 but I have the manual sliding window. And of course, everytime I atempt to take it to the dealer it stops rattling on the way.

Any suggestions?
This is my 3rd ford truck and the 1st one with any issues. Starting to get upset.

 

The fixed the leak but the rattle is still there. I've given up on trying to track it down.

 

I also had this rattle and it was very noticable while I was out hunting traveling on the back roads. After a few days I noticed that it occurs mostly when the truck is warmed up. Took it into the dealership yesterday, forman called said he could not find any noise. I told him I was not surprised as it was cold and raining out. They know me well there and I was not surprised that when I went to pick it up he came out and told me that he found a TSB about replacing the lower track on the sliding window and that the parts were on order.

Dave

2004 Screw Lariat

 

I'm glad they have a TSB on this, my truck sat outside overnight and the temp got down to about 20 degrees and I had a wicked rattle on my way home. Thanks for the info guys, now I know what to tell the dealer.

 

I have the same exact problem, plus another.
2004 Supercrew FX4 with the power-slide rear window


1. The rattle at the rear of the cab, seems like under the window area, behind the seat. Can't find it. But it's there.

2. With the rear window open, a terrible, cricket-like, high pitched, non-stop squeeking noise while moving.. close the window, noise gone.. cant be sure if its outside in the bed, or the window itself.


ideas?

 

I have the powerslide rear window and mine only makes noise when the window is opened at all. If I close it there is no noise what so ever.... I wonder if your 'cricket' noise is what I am calling a rattle..?

Either way, looks like I will be bringing it in for the TSB above.

 

Just noticed mine has that too! I thought it was the rear sliding window, but then I press up on the headliner behind me and sure enough! Nice quality ford, stupid *** rattle box

 

My 04 Screw FX4 is going in today for the 3rd time (8000 miles) for the sliding rr wdo squeak. The first TSB didn't work (1500 miles) , the 2nd new & improved TSB didn't work (4500 miles) now the QC person at the dealer is involved w/the Ford rep. Apparently I am getting a whole new rr w/do assembly. My confidence is not high at this point. Stay tuned!

 

All the same noises as mentioned above. Dealer replaced the entire rear window assembly no charge! No more squeak\rattle for me.