Air leak/wind noise (deafening whistle.)

[meekodactyl]

My door has a some sort of air leak, I’ve seen others post similar issues. There is a deafening whistle at 60mph+ and the recirc off on the hvac. Wind noise is awful as well. Ford dealer replaced the door seals with absolutely no improvement. Then they used RTV on the mirror and some other random places with no improvement. The dealer is now saying this is normal operation. Any help would be so appreciated!
Additional info: I have a 2025 lariat eco boost so I do have the additional wind insulation in the wheel well area. The tape is just me trying to find a source of the leak.

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[bighap]

Your dealer is full of it. I have never heard a whistle like that on my truck.

 

[Glen Baker LLC]

Adam,
Welcome to the forum.

My door has a some sort of air leak, I’ve seen others post similar issues. There is a deafening whistle at 60mph+ and the recirc off on the hvac. Wind noise is awful as well. Ford dealer replaced the door seals with absolutely no improvement. Then they used RTV on the mirror and some other random places with no improvement. The dealer is now saying this is normal operation. Any help would be so appreciated!
Additional info: I have a 2025 lariat eco boost so I do have the additional wind insulation in the wheel well area. The tape is just me trying to find a source of the leak.

Now to your post and video.

WOW that sucks. That is not normal.
Does the whistle change with HVAC settings on normal versus recirculate and the speed of the fan?
The dealership that says that this is normal is full of

I'm going to suggest something that might be a little difficult to do. If you can have someone stand safely by a road where you can drive by at speed and they can tell you how loud the whistle is. That will at least determine whether the whistle is outside (mirror, door handle) think the area where the the gap where the mirror rotates when you fold it in. It doesn't take much to cause a whistle
OR is it inside the vehicle.
It's going to take some troubleshooting.
Great Video by the way.

 

[icegradner]

My door has a some sort of air leak, I’ve seen others post similar issues. There is a deafening whistle at 60mph+ and the recirc off on the hvac. Wind noise is awful as well. Ford dealer replaced the door seals with absolutely no improvement. Then they used RTV on the mirror and some other random places with no improvement. The dealer is now saying this is normal operation. Any help would be so appreciated!
Additional info: I have a 2025 lariat eco boost so I do have the additional wind insulation in the wheel well area. The tape is just me trying to find a source of the leak.

Yeah that’s not even remotely normal. If you can, try a different dealership.

 

[Fcnrwy]

Mìne is a lowly XL (Oct.31 2022) build..
Have never heard any thing like that..
Q. When this door is closed (cant tell, assuming it is a door rear). How is the exterior finish, body seam.
If gaskets are Not working. The door must be warped..

Jerry

 

[Aherpa]

My door has a some sort of air leak, I’ve seen others post similar issues. There is a deafening whistle at 60mph+ and the recirc off on the hvac. Wind noise is awful as well. Ford dealer replaced the door seals with absolutely no improvement. Then they used RTV on the mirror and some other random places with no improvement. The dealer is now saying this is normal operation. Any help would be so appreciated!
Additional info: I have a 2025 lariat eco boost so I do have the additional wind insulation in the wheel well area. The tape is just me trying to find a source of the leak.

Definitely not normal . . . does the door have a good fit? Does it lay flat with the rest of the body panels? Is the gap around the door uniform or does it vary? Take a look at all of rubber seals, are they flat in places (like the corners), do they make contact all around the door. To find ill fitting seals, place a strip of paper across each seal (not both at the same time) and close the door. If you can easily pull the paper out with the door shut, there is a problem.
Good luck.
If you find something, take it back to the dealer, it's their job to fix it.

 

[dhaskit]

Not normal.
Very annoying.
Suggest finding a different dealer repair shop.

The good news is, you won’t have to buy those little sonic deer whistles to install on the front bumper. (they actually don’t work anyway).

Good luck to you, my friend.

 

[scott1070]

Are your windows rolled up all the way? Maybe one creeped down a bit

 

[meekodactyl]

It’s definitely not that, thank you though

 

[meekodactyl]

Not normal.
Very annoying.
Suggest finding a different dealer repair shop.

The good news is, you won’t have to buy those little sonic deer whistles to install on the front bumper. (they actually don’t work anyway).

Good luck to you, my friend.

 

[meekodactyl]

Thanks for the humor, I need it. Unfortunately it’s only inside lol.

 

[not null]

Seems like it would help if you could identify exactly where the problem is.

What about (temporarily) tape some pieces of paper (toilet paper?) around where it could be to see if they flutter? Something like a sailboat tel : https://www.amazon.com/Davis-0011698009503-Air-Flow-Tels/dp/B001446RLM

As @Fcnrwy suggested, maybe it is something weird like a door is warped somehow.

 

[Fcnrwy]

The tape is just me trying to find a source of the leak.

After studying your video..
Does the area around the Driver's window look like these...

Driver's Inside seal..

Driver's Outside seal.

The image of the blue tape, "Flapping in the Breeze", suggests the "Window seal(s)" are not seating...

Jerry

 

[meekodactyl]

After studying your video..
Does the area around the Driver's window look like these...

Driver's Inside seal..

Driver's Outside seal.

The image of the blue tape, "Flapping in the Breeze", suggests the "Window seal(s)" are not seating...

Jerry

Let me check thanks for trying to help out.

 

[meekodactyl]

Adam,
Welcome to the forum.


Now to your post and video.

WOW that sucks. That is not normal.
Does the whistle change with HVAC settings on normal versus recirculate and the speed of the fan?
The dealership that says that this is normal is full of

I'm going to suggest something that might be a little difficult to do. If you can have someone stand safely by a road where you can drive by at speed and they can tell you how loud the whistle is. That will at least determine whether the whistle is outside (mirror, door handle) think the area where the the gap where the mirror rotates when you fold it in. It doesn't take much to cause a whistle
OR is it inside the vehicle.
It's going to take some troubleshooting.
Great Video by the way.

It’s definitely inside when I push the door panel in the whistle dies down. It’s much worse with with recirc off on low settings.

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