As has already been pointed out there is a mod for this. It is very popular on other ford diesel sites. I had the same issues with my 05 Ex. with noise wind etc. Also had a kinda "dead" door. Would not pop when you open it. Passengers could not tell if it opened, and you had to push or pull it to to get the door off the nader pin.
Anyway, great mod. Get latex surgical tubing MUST be 3/8"OD 1/4"ID. Web search or amazon has it. Other sizes either wont pull through the weather stripping or will be too small to hold the stripping out to make a good seal. You will also need two cans of silicone lubricant. Mark where the two ends of stripping come together on the kick plate with a pen on a piece of masking tape. This way you can reinstall the stripping in exactly the same spot. Pull out the stripping (very easy) and straighten all the curves out best as possible. Push the fish tape through the stripping and connect to the tubing. Use lots of lube on the inside of the stripping and use the fish tape to pull the tubing back through. Reinstall stripping. I did all four doors on my ex in about 90 min. with a beer break in between.
After the mod, WOW. all doors pop when you open them, wind and road noise is much diminished. Simple cheap mod. Also works on other vehicles.
As noted by Jason above, thats about the going price for 50ft. and that should be enough for all four doors. The roll probably wont be one continuous piece but no worries. Tape it and pull it. Tubing will stretch a bit and not quite pull back to normal.
Last edited by kawika904; 03-08-2013 at 02:55 PM.
Reason: Forgot something