My car is driving me nuts. It's had a fair bit of work done since I bought it in 2015 and it's a MK2.5 1.6 100ps. It has had a dash/windscreen rattle issue for so long and it won't go away no matter what is changed/renewed. So far it's had..

[*] Control arms front 

[*] Sway bar links

[*] End links

[*] Passenger side mount

[*] New rear springs (1 snapped)

[*] Rear upper arms (replacement tomorrow) 

Tyres are new all round and I service it regularly. There is weird symptoms for example if I cross over a small hump in the road one like where they have filled a crack too high it feels like when we would trip over something. The dash makes a racket and the windscreen resonates like it's going to jump out. This happens in most cracks and bumps in the road and tracking has been done recently also. The odd time the dash will start crackling itself going along rough surfaces. Is it possible for the strut mount bolts to get slack over time? Or could it be worn struts? I'm at my wits end here now lol 

Sounds like you have replaced most of the suspension components that would cause suspension noise.  However what concerns me is the noise you say is coming from the windscreen which is very odd this shouldn't make any noises at all.  Has the car had a replacement windscreen as it sounds like its not bonded to the car correctly.  The dashboard noise is also strange has this been removed at all?  If so its almost impossible to fit it back to factory standards which will cause noise.

3 hours ago, JONATHAN_11_80 said:

Sounds like you have replaced most of the suspension components that would cause suspension noise.  However what concerns me is the noise you say is coming from the windscreen which is very odd this shouldn't make any noises at all.  Has the car had a replacement windscreen as it sounds like its not bonded to the car correctly.  The dashboard noise is also strange has this been removed at all?  If so its almost impossible to fit it back to factory standards which will cause noise.

I found my dash went back no problems at all with no rattles but I 100% agree with the comment about windscreen bonding.

3 hours ago, JONATHAN_11_80 said:

Sounds like you have replaced most of the suspension components that would cause suspension noise.  However what concerns me is the noise you say is coming from the windscreen which is very odd this shouldn't make any noises at all.  Has the car had a replacement windscreen as it sounds like its not bonded to the car correctly.  The dashboard noise is also strange has this been removed at all?  If so its almost impossible to fit it back to factory standards which will cause noise.

Not that I'm aware of and I have not had any done but I'll investigate them thanks.

It's probably had a screen...  My dash has a rattle since the screen was replaced as well.  It's only at certain idle frequencies or harsh bumps but it's very annoying this time of year and one reason I put off having a new screen for so long, the same happened on previous cars.  The screen itself shouldn't rattle though, it's effectively a structural part of the chassis!

Tap round the plastics, the dash, the A pillars, the interior light, etc. Plenty of stuff around that may be loose and tapping (if you do not push the A pillar trim all the way flush, it can tap against the windscreen under the right conditions). You can also pull them off and check that you are not missing any / have any broken trim clips here.

The chap who fitted my windscreen managed to bond one of my A pillar trims to the screen... luckily nothing a stanley knife can't fix!