Dashboard defrost vent rattle; TSB 24-2317doesn’t cover FX4 models BUT IT SHOULD - Buyers beware

[rmauri]

My ’23 Maverick XLT FX4 had a persistent dash rattle that sounded like it was coming from the windshield/defrost area.

After some poking around, I found the cause:

• On the passenger side, if you stick your finger into the defrost vent and pull toward you (away from the windshield), the duct doesn’t move. There’s a factory foam pad under there that keeps it solid.
• On the driver’s side, do the same thing and you’ll feel/hear the duct scraping against the underside of the dash. No foam pad from the factory. That’s where the rattle comes from.

Temporary fix I used:
I slid a piece of cardboard between the duct vent and the underside of the dash on the driver’s side. Rattle instantly gone. A more permanent fix would be adding a strip of adhesive-backed felt or foam (like the OEM passenger side uses).

Takeaway:
Ford already knew this was a potential vibration issue — they put foam on one side but not the other. It matches the condition described in TSB 24-2317, but that TSB doesn’t cover FX4 models, so the dealer wouldn’t fix it.

So if you hear an annoying dash rattle in your Maverick, check the driver’s defrost vent. It might be as simple as shimming it.

Buyers beware — this is a known design oversight that Ford hasn’t officially addressed on FX4 models.

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[CajunMick]

Good info. My dash rattled. Until now….added a rubber molding in the space between windshield and leading edge. No more rattle. But do get a knock when driving over more harsh roads.