Fusion 06. Zetec. In hot weather a fairly a loud and constant rattle was emitted from the passenger side dash moulding, Ive read of others experiencing this. Try as I might I couldnt figure it. Long story short...
The meeting line between the light coloured moulding which decends from the roof and the far left upper dash moulding...moves considerably when hot. Not so bad when cooled down. The solution was a small piece of black expanded foam (poly underlay) about 20mm X 15mm pushed into the narrow gap between the mouldings right by the windscreen. Its not noticable when in place. To be sure I put a piece in drivers side too.
Problem over.. Deep Joy! J.

Good thinking!