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On my drivers and passengers doors, after many years of sun, I had to replace the anti-rattle inner and outter on both doors. These are the horizontal fuzzy pieces that just snapp in and out of the door. I ordered some from Dennis Curt and when they arrived the inner one was a great fit, but the outter one second from the end was about an inch off. When I called and told them they said my door was wrong.
I then ordered some from LMC and the same thing. The second one from the end on just the outter ones was off. The inner ones fit great.
It really upsets me when they tell me, LMC, that we just had our department try it on and it works great. Something must be wrong with your door. We sell about 25 of these kits a month and no one has complained.
i have had so many of these trucks- i think that one of the tab locations on the older trucks are in a slightly different location. being that they made these trucks in so many different places, it is not surprising. so some aftermarket suppliers used an older door for a test fit and some used a "newer style" door. that is my theory. At most all you have to do is snap off a tab, it will still work.
The OP never stated what year his truck is, it's a moot point anyway, all the 73-79 doors were from the same stamping regardless of location so i'm not sure i subscribe to your theory.
I recently replace them on a 78 I restored. Check and see if you have the wrong inner on the wrong door. I was trying to place the drivers on my passenger and realize it was off set.
Maybe the same issue with yours or not.
Just a though.
It's been that way for years... if you do a search on the forum the anti-rattle problem goes back well past 2001. So, it isn't a new problem. I can see why guys don't call LMC or others about the problem, because probably like me, I just dealt with it.
I installed new ones in 1995 and had that problem. Just snipped off the problem tab. I don't remember exactly where I got those, but I am about 80% sure it was Ford.
I installed new ones again after a minor resto in 2001/2002 and had the same problem. I was able to move the tab and reattach it. These came from LMC.
This last time I had no problems. Blue Oval truck Parts.
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