So lately I've been having a very obnoxious rattle in the left rear door of my '04 Scab FX4. Sounded like something had come loose and was rattling inside there. I finally got around to taking apart the door and scoping things out to find that there were pieces of some sort of hard, black, coating that had apparently been sprayed onto the inside of the door and broke off and came loose. So every time i had gone over some uneven ground it would rattle around. I actually removed a decent sized portion of that material. Is this some sort of sound dampening material that I should replace (when it gets warmer)? Thanks.

 

No, don't worry about it. It fell off, I doubt you notice a difference, so just leave it.

 

While that could be the case, I would go back to my dealer (if you're still under warranty) and have them replace the mastic pads on both rear doors of your Scab. The '04 Scabs have a not so nice feature of getting waves in the rear doors due to a poorly designed OE pad put in the door. My Scab got the waves, and a new mastic pad was put in, and all has been well. If yours is coming off, I'd get it replaced, to avoid the ripples later.

 

Good point, I personally wouldn't worry about it, but you may want to get it redone to prevent the possibility of this happening.

Thanks BigTRQ.

 

Since my warranty is up, would it be possible to spray the inside w/ a good dose of hurculiner?

 

• BODY—REAR DOOR PANEL—WAVY APPEARANCE Article No.
IN COLD WEATHER—LOUD RINGING UPON 03-26-4
CLOSING DOOR—RATTLE INSIDE OF DOOR—
VEHICLES BUILT BEFORE 11/12/2003
• NOISE—REAR DOOR PANEL—WAVY
APPEARANCE IN COLD WEATHER—LOUD RINGING UPON CLOSING DOOR—RATTLE INSIDE OF DOOR—VEHICLES BUILT BEFORE 11/12/2003 FORD: 2004 F-150
ISSUE
. On some 2004 F-150 Supercab vehicles built before11/12/2003, the rear door panel outer surface mayexhibit a wavy appearance in cold weather.
door may also exhibit a loud ringing upon closing,
or a rattle noise may be present inside the door.

ACTION .
To service, install a Permacel Mastic Patch
(4L3Z-18203A16-AA) to the door outer panel. Refer
to the following Service Procedure.

SERVICE PROCEDURE
. 1. Remove the rear door trim panel per Section
501-05 of the Workshop Manual.
2. Peel back the water shield to access the inside
of the mastic. .

. 3. Inspect for the presence of mastic material on
the door outer panel. If none is present,
. proceed to Step 7.
. NOTE
THE MASTIC MATERIAL MAY HAVE FALLEN
DOWN INTO THE DOOR. REMOVE ANY LOOSE
PIECES FROM THE BOTTOM OF THE DOOR.

4. From the outside of the door, place an
Infra-Red paint curing lamp 46cm (18²) from
the door sheet metal surface in the area of the
mastic patch. Heat the door for 3-7 minutes at
180°F.
5. Remove the heated mastic material from inside
6. Remove any loose mastic pieces from the
The bottom of the door.
7. Apply Motorcraft PM-12-A Low Temperature
Anti-Corrosion Coating to the original location of
the mastic material
NOTE
THERE WILL BE A VISIBLE WITNESS MARK
(UNPAINTED PORTION) INSIDE THE DOOR
INDICATING THE LOCATION FOR THE NEW
MASTIC MATERIAL
8. Install Permacel Mastic Patch
(4L3Z-18203A16-AA) over the original location
Press the mastic patch of the door
thoroughly in place, especially on edges and
corners
9. Reinstall the door watershield
10. Reinstall the door trim panel
PART NUMBER PART NAME
4L3Z-18203A16-AA Mastic Patch
PM-12-A Low Temp Anti-Corrosion Coating

 

Damn I have this problem, was not sure what in the hell it was. How did you remove the rear doors trim, what holds it in (screws + clips or just clips).

 

My '06 is flawless still, :whogives: ....Karma? (not that a believe in that bologna)

 

The panel is held on by screws, two at the top behind the 2 trim pieces that extend up. Those just snap off. Then there's one screw at the bottom. You will have to remove the window switch panel which snaps off real easy to get to another screw. The final 2 screws took me awhile to find, but if you look behind the door handle there's a little panel that comes off to reveal the final two screws. I then removed the speaker to be able to get into door itself and remove the broken pieces. Ill end up spraying the new stuff in the same way when it gets a little warmer.