Hi all, I have a 2017 Chevy Express Cargo Van. This is a work van for me and was recently purchased. I’ve noticed an incredibly loud and annoying rattle coming from the headliner area in the cockpit. It only happens when I’m going above 45mph and after the van has been sitting in the sun for a while (never happens on the interstate in the morning after the van has sat overnight).

I took the headliner down today, at least at the back part of it because it sounded like a wiring harness or something slapping against the roof of the van. I didn’t see anything flopping around up there so I am a bit stumped. I do have a ladder rack on the roof with two ladders strapped down but the straps are tight and no flopping ends on either one.

Any insight would be greatly appreciated! This rattle is insanely loud!

 

did you try driving around with the headliner removed to see if noise persists?

 

I removed the clips and visors from the headliner and let it rest on the seats, so it was essentially just hanging there, and then took it for a drive. The noise was still there and I didn’t see any wiring harnesses or anything that would be causing the rattle. I didn’t want to remove it fully because the wiring to the dome light was glued onto the headliner. I figured that would cause more problems if I removed the glue.

I also took both ladders off the rack thinking they might be loose enough to cause the rattle but no luck there. I’m still stumped.

 

You don't need to remove any glue. The harness was glued in before the headliner was installed in the van. You unplug it at the A-pillar.

Maybe when you get going fast enough, air pressure lifts/rattles the roof skin against the cross ribs. Try stuffing some shims up there

 

The speed requirement points to something outside the van. If it was inside under the sheetmetal it would happen at any speed.

 

Now that I think about it, these are notorious for the top corners of the windshield weatherstrip coming loose, although I've never heard of one flapping enough to make noise before. But it would fit both the speed requirement and the warmth requirement - and maybe not immediately be obvious.

If you had a GoPro with a good suction cup mount you could when the van is making the noise put it on the roof and record a minute or two and see if you can see anything moving.