Volvo Forum member Mustang explains his 2001+ “P2” Volvo door rattle fix: “Since I’ve owned my 2006 XC70 I have always had a nasty rattle in my drivers side door. It made a racket when I closed the door, went over bumps as well as when listening to music.
I finally took the door apart and found the culprits. It appears Volvo attached the power window assembly plus a few miscellaneous brackets to the door frame with rivets. Over time these rivets got quite loose. I drilled the rivets out and replaced with bolts and rubber lock nuts. The rattles are gone and I am happy. I’ve uploaded a couple pictures showing which rivets I took out, the rear window guide was the biggest culprit and was extremely loose. I only replaced the loose rivets and left the others alone. I hope this helps someone, looks like a bad design flaw to me.”
IVIUSTANG » Following this fix I also used GTMat on my doors(Dynamat clone) and used 3M thinsulate on the inside of the removable door panel as well. The bass is incredible and there are no rattles from any of my doors anymore! I also did a fix for the creaky seats and rattling B pillars in these cars. In addition to this I put some felt tape under a squeaky panel in the centre console; furthermore I also disassembled the centre console cubby lid which is notorious for squeaks and creaks; I put felt tape under every contact point and snap on the lid and it made a world of difference. I am pretty happy overall with the lack of rattles and squeaks in my car now!
IVIUSTANG » I found another possible rattle source in the P2 cars the other day. It appears the cable between the door handle and latch mechanism can slightly stretch over time causing slack in the cable and a possible intermittent rattle, I sourced the exact cause by slightly pulling on the door handle from the inside and found that it had a little bit of play in it before it would start pulling the cable; the noise would also disappear as as soon as I put this tension on the the cable.
I bought a bunch of assorted tiny O-rings and picked the smallest one that I could squeeze over the metal piece on the door handle side of the cable; I then re-installed the cable and the rattles have not returned since. I have attached a picture of what it looks like, you may need more or less O-rings depending on how slack your cable is.
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Same side, same rattle in my 2004 X70. Drives me crazy !
My wife can’t hear it or just ignores it !
Never got it fixed under warranty and now the problem will cost me $$$$, if I want to solve it at last.