My '09 250 has been into the local dealer a couple of times for a rattle located behind the glove box. This is a rattle that coincides with bumps in the road. First attempt was to replace a blend door actuator that appeared to be installed pretty deep within the dash assembly as the replacement required a hefty disassemble of the dash . This did not fix the rattle so I took it back. They worked on it for a couple of days, stuffing foam here and there and examining some of the electrical systems. I took the truck after a few days because they were stumped as to the cause of the rattle. I continued to work with the service team and waited for the Ford engineer to develop an opinion. His evaluation, without even seeing the truck, was that the rattle was consistent with the make, model, and year of the vehicle. Does that mean that Ford is building these rattles into trucks as a "feature"? I called customer support and the agent listened to my story as she took notes. She went off line to call the dealership and...wham, we hit a stone wall beyond further options. Apparently once a Ford field service engineer makes an evaluation, Ford will not budge to consider any further options. That is any further options that don't cost the consumer $$$. Guess it's time to fix it myself.

 

Had a 09 that had a similar rattle! It was a combination of the air bag connector hitting the dash bracket and the a/c plenum being loose.

 

Thanks...I will into these possibilities.