I have been chasing a door rattle on the right hand side door for the past several months, including messing around endlessly with hinges and door catches. I have recently figured out it wasn't any of those and is actually the window. When fully closed the rattle is there and very noticeable over any road imperfections. However, if the window is partially opened (even a tiny amount less than half an inch) the rattles disappear. So it is probably the window, even though the sound feels like it is exactly level with my right ear.

Any idea what this could be? I would ideally like to order the part's before going through the effort of taking out the door card/etc... so that I don't have to disassemble, figure out what is missing, order parts, reasssemble, disassemble once parts arrive etc...

For what it's worth the window runner was definitely not rusted last time I looked in May of last year and was in pretty new condition (I think a previous owner must have replaced it). Could it have rusted in 8-9 months? probably but unlikely.

 

Hi NK,
The noise may be from the hard glass coming in contact with a hard part of the frame or along the bottom where it passes through the body. You may not need any parts as all. If you can find where it is contacting you may be able to move the rubber buffer around or even add a little 100% silicone bath calk in the channel as a buffer. Let it fully dry and it will form a rubber-like buffer between whatever hard part is touching the window.

Alternatively, if the door has ever been opened up for servicing or a speaker replaced look internally to the door for a loose wire or even some loose insulation, it is known to break loose from the outer door skin, that rattles around more when the window is up giving it greater free space in the door to move around and make sounds.

Just some thoughts concerning getting a solid root cause diagnosis before throwing money at parts.
Andy

 

This may give some insight :- Para 17 http://www.jackals-forge.com/lotus/9...ry.html#window

 

Take a look at the sound deadening material that is hard as fiberboard and falls off the inside of the door skin. It may be banging around in there. Just a thought.

 

My sound insulation is new (from May). It’s also the main reason I’m dreading taking everything apart because I’m certain I won’t be able to do as good of a job as the guy who did the doors for me:

 

Wow that’s some sound deadening job. So much for my theory. Why not take the car back to this shop and see what he can find?

 

Somehow I think the rattle may be the result of the major aftermarket intervention on the door where insulation was added and the entire wiring harness was disturbed.
Andy

 

I doubt it is the deadening. The noise only started after one **** workshop adjusted the hinges (half a year after the deadening), which is why I assumed it was the hinges/door catch initially. I assume with all his banging around he loosened or broke something.

anyway, with regards to adjustments, does anyone know specifically what each bolt below is responsible for ? I have labelled them for convenience: