Thought this might help, or at least worth a try. Originally posted as "Annoying Rattle Part 2.
"Hey guys,
Thought I'd update you re: door rattle. As I have mentioned before, I traced the rattle to the lower door hinge. After fudging around with remedies (penetrating sprays, oils, grease, dry lube etc, etc...), I decided to try a physical fix. Went to clark rubber, purchased a strip of 16x16mm high density foam rubber, cut it to size and stuck in in the door jam near the lower hinge (theory behind this is to have it place outward pressure on the lower hinge to prevent excess movement), and hey presto, noise gone!"
Good luck...
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