I have the same seat rattle. It sucks. I also have the tire jack kit making a ton of noise in the back. Despite packing the compartment with rubber pieces and rags.Dude, I've been chasing this rattle forever! It's been to the dealer twice. I thought it was the door. They tightened everything down, did the window guide adjustment, and just couldn't find it. This weekend I finally dug into it myself and after disassembling the door, going through everything, and driving around with the door panel off I finally figured out it was the seat.
Specifically, its the seat rails. You'll find if you move the seat all the way forward it doesn't do it. There's the rail that's attached to the seat, and the rail that's attached to the floor. The seat rail slides inside the floor rail as you move the seat back and forth. These two rails are banging against each other over bumps.
If you look in there with a flashlight, there's a strip of blue plastic towards the front, that kinda acts as a "guide" for the inner rail, and stops excessive movement. Ford, in their infinite wisdom, decided this guide didn't need to extend the full length of the rail. So when the seat is about halfway or more back, there's no support and the rails start rattling together.
It's fuckin infuriating, and I can't believe you're the ONLY other person I've seen mention it.
Unfortunately I have no idea how it can be fixed.
My wife’s two door base doesn’t make a sound. My badlands sound like a tin can full of bolts.
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