My '05 pass door rattles on a rough road too. If it was "normal" why wouldnt the drivers door rattle also? At first I thought it was the jack parts, but took them all out, but still had the noise. Seems like cab flex, or not enough weatherstrip to keep doors tight to jamb. Thought about adding a 1/2" strip of door weatherstripping where existing strip makes contact.

 

Heard of guys replacing weatherstripping to fix rattle. Dont know outcome. Why would weatherstripping wear out on passenger and not driver first? Makes no sense. I think it is latch. I have to fix lock anyways so I might change latch at same time will post results. Probably not going to happen soon not high on the priority list.

 

Mine does the same thing, Like Bigbluemackdaddy said I think its because the doors are short and light, the doors only rattle on dirt roads and bumps.

 

One thing I did find on inspection of passenger door[also found on drivers door] was the spot weld was broken between interior panel/exterior panel [bottom rear corner of door]. Drilled out and fixed with small stainless bolt/lockwasher/silicone. Did help with some rattle/thump. This is on '01 F350. I am pretty convinced it is latch making door rattle/thump.

 

I just got my drivers side door rattle fixed today on my 07 Lariat. Along with all four windows that squealed I wanted to get rid of this truck. With a striker adjustment and four new regulators I actually like driving my truck again. Gotta love warrantees. My warrantee expires next year so I may have to extend it to avoid future probs. Can't imagine what they would have charged for that fix.

 

I have an 06 f-150 S-crew. My driver and passenger side doors rattled..started to get worse. I wrapped the striker bolts a few times with electric tape and it solved the problem. Curious to see how long the tape lasts though.

 

I have this same issue, just sounds like the doors aren't shut all the way.

A friend suggested replacing the weather stripping cause it has no resistance to compression anymore, (which makes sense) but i haven't tried it....