2024 XLT-Driver Door Issues

[NinerK]

Anyone else have issues with Driver Door?

Purchased September 2024, Driver Door Hinge started clunking in June 2025. Dealer #1 (where I purchased) kept the truck for a few days, sent to body shop....body shop reset the door. Clunking gone, but a significant air leak is present.

Took to Dealer #2, they heard the air leak, replaced door seal and told me they no longer heard the air leak. The air leak is still present.

Took back to Dealer #1, took a test drive with tech, could not hear the air leak. Dealer #1 wants to take a deeper dive, which is good, but I'm not confident they will do anything without being able to duplicate.

Have taken videos, etc. During winter there is actual COLD AIR blowing into the cabin. I live in a rural area, so when I am driving on a rural road with no other traffic it is easy to hear. Take it to the dealer and on the test drive to listen for noise there are so many other cars on the road you can not hear the air leak.

Kind of a vent post; super frustrating because the door was removed from the frame, and after that this air leak started.

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[mrmike7189]

Super frustrating. Ford QC is crap these days. I still have 3 recalls that I havent had fixed yet.
I also have a drivers side door air leak noise on my 2024 Ranger XL/STX.
I've learned to live with it, but when I have a free day off I will deep dive into finding it.
It seems to be behind me so behind the drivers seat up near the seatbelt adjustment post.
I'm hoping its just a window seal and I can fix it myself.
Good luck in your search for silence.

 

[NinerK]

Super frustrating. Ford QC is crap these days. I still have 3 recalls that I havent had fixed yet.
I also have a drivers side door air leak noise on my 2024 Ranger XL/STX.
I've learned to live with it, but when I have a free day off I will deep dive into finding it.
It seems to be behind me so behind the drivers seat up near the seatbelt adjustment post.
I'm hoping its just a window seal and I can fix it myself.
Good luck in your search for silence.

That is the EXACT SAME LOCATION as the air leak on mine. The hood was misaligned as well and there was tape/paint remnants on the hood edge up by the windshield. All that was fixed.

Love the truck.....even with these issues it has not been in the shop half as much as my 2021 Toyota Rav 4-That was in the shop for at least 6 issues including replacing the fuel tank

 

[Trimjb]

Super frustrating. Ford QC is crap these days. I still have 3 recalls that I havent had fixed yet.
I also have a drivers side door air leak noise on my 2024 Ranger XL/STX.
I've learned to live with it, but when I have a free day off I will deep dive into finding it.
It seems to be behind me so behind the drivers seat up near the seatbelt adjustment post.
I'm hoping its just a window seal and I can fix it myself.
Good luck in your search for silence.

A member made a post on solving the noise behind the driver. He added a secondary piece of weather stripping which resolved the noise.
Maybe a search or someone will remember the post here.
So far I have learned to live with the little noise I have on the XLT.

 

[mrmike7189]

That is the EXACT SAME LOCATION as the air leak on mine. The hood was misaligned as well and there was tape/paint remnants on the hood edge up by the windshield. All that was fixed.

Love the truck.....even with these issues it has not been in the shop half as much as my 2021 Toyota Rav 4-That was in the shop for at least 6 issues including replacing the fuel tank

If you find the spot..let me know. I'm thinking its the weatherstripping on the rear passenger door

 

[NinerK]

If you find the spot..let me know. I'm thinking its the weatherstripping on the rear passenger door

The air leak on our truck is coming from the upper left hand corner, as if the glass is not fully seated in the gasket/weather stripping.

It has been with the dealer since 08/19/2026 as they methodically go through taping different sections. I submitted video where I run the mic left to right along the top weather stripping, where the glass is seated. You can hear a significant difference in air noise, and the Service Advisor and Manager have both said they can hear it....the technician has not diagnosed it though.

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