I had a noise in the lower windshield area. It was the plastic filler under the wipers, when I tapped it down I could feel the clip snap in, been quiet ever since.

 

I agree with this. Go on the passenger side and push on the black cowl and listen. I have examined this and have yet to fix mine. It is the only noise I have. I did have a center console door noise that I fixed with a little grease.

The cowl is attached to the truck with "push in" interior type clips under the hood, there are two of them on the passenger side. If you remove and pull up a little you will see the cowl has "hooks" that is suppose to go under the windshield to hold it "tight to the glass", then you use the push in clips to attach under the hood. The issue is the passenger side is not to tight and the cold rubber against the glass and hood pushing on it makes a "creak" noise. I suppose some grease or vaseline on the underside of the rubber seal may help, but that would be a temporary fix. I also thought it was a pillar type issue at first, but could never duplicate it by pushing/moving the pillar.

 

i live in fl. so it always a little warm the last time i got to drive my truck (i'm TDY) was jan. temps were 50's in the mornings and 80's in the afternoon but happened both times of day. i use a concrete road with expansion joint in it for my commute, that's when it was the most annoying and if i put my hand on the head liner it stopped. taking it to the dealer only help for a little while.

The headliner uses plastic velcro to hold it up around the sunroof frame, mine was never hooked together on the drivers side, it made noise when cold. If you open the sunroof and stick your head up and look in between the headliner and sunroof frame you will see the black tabs of plastic velcro, you should be able to snap it together.

Just something to check.

how do they attach the Velcro? it wasn't the sound Velcro makes not even the industrial strength plastic Velcro.

 

I had a similar noise that only occured when i went over bumps--temperature also made a difference in the beginning but it eventually got worse. I tracked it down to the headliner. As suggested I pushed on the headliner in various places trying to get the velcro to stick but it never worked. It eventually got so bad that I took it to the dealer, drove the tech around so he could hear it. They said there is a wiring harness that runs between the headliner and roof that had double sided sticky tape on it that came loose and the harness was rubbing the headliner. They re-taped everything and I haven't heard the noise since---that was about 4 or 5 months ago. I don't have a sunroof and I don't know how far they had to drop the headliner to fix it. I'm pretty picky and I think they did a good job putting everything back together.

 

It is the plastic type Velcro, it has a double sided stick tape on it which attaches to the braces on the headliner (the braces are glued to the headliner, I had to epoxy mine because the glue came undone) the other side of the velcro is on the sunroof frame. It makes a weird noise,but in my case it was the velcro, mine wasn't even stuck together, it did only do it when colder.

I am a mechanic at a Honda car dealer and we have the same stuff on our headliners, so before anyone complains about plastic velcro holding their headliner up, it is common in other vehicles, at least in the last few years. You would be surprised how many designs are similar between cars.

 

as dumb as this sounds buckle up all the seat belts. I over looked that and ended up searching for the rattle for an hour. the bolstered seats on the trucks leave little room between the b pillar and the seat it self. the buckle rattles against the plastic... at least it did in my truck.