I've cured this problem in my 2007 Fusion. The door rattle eminates from the window-switch unit in the door panel. The actual window-switch unit is clipped into another plastic chassis that houses the window lock-out, window, and mirror controls. This is the the plastic chassis that you grab when you open and close the door. To cure the problem you will need to wrap the actual window-switch unit to the chassis more securely. Start by removing the plastic chassis from the door panel. You need a size 7mm socket to remove the screw inside the handle pocket. Pull up on the plastic housing and slide towards the left to undo the clip near the mirror control knob. The chassis should lift directly out. You can leave the switches plugged-in. Simply take small strips of electrical tape and pull the sides of the plastic chassis tighter to the actual window-switch unit. Do this in several areas around the chassis and switch and you have your cure for the terribly annoying door rattle. I couldn't believe that such a small plastic clipping method would make such an annoying rattle. Thanks for following the long reply.
