We bought our 2003 4.4i in October and knew of the knocking/tapping/tocking coming from the rear tailgate area as we signed the paperwork. We took it back into the dealer (CarMax) to have it addressed a few days later. They fixed it, but a few days later, the sound returned.

I searched Xoutpost for the remedy and considered a couple of possible fixes. I carefully removed the plastic covers from the inside of the lower gate, removed the insulation and made sure there was nothing rattling around in there. Satisfied, I put that back together and began removing the upper tailgate hatch inner panels and trim. There are a number of wires running along the top, behind the 3rd brake light, some of which hang somewhat loosely and could be a source of some noise. I used a few pieces of electrical tape to secure these, just as I did with the wires hanging near the windshield wiper motor. I think this may prevent some more high frequency tapping I've been hearing.

What really fixed it, though, was adjusting the two stops that the upper gate closes against. The dealer had applied grease to the stops, each having a T25 Torx bolt through the center. I unscrewed the Torx bolts, removed them and cleaned them. The rubber stops have a threaded steel insert that allows them to be threaded onto the body. I imagine that these can be adjusted, using the Torx bolt to hold them in the desired position. They have a 6mm hex pattern hole visible after you remove the Torx bolt. I removed them completely and cleaned the grease off of them, then spun them back onto the threaded posts attached to the body, tightening them all the way down. I then replaced the Torx bolt, shut the hatch, checking for anything abnormal. After driving the car for a few hours today, I am VERY happy to say, it is fixed!! The car is drum tight and the tailgate closes just like it should.

These cars are too awesome to have such a simple problem detract from the driving experience. It's an easy fix.

I hope this long post will help someone with the same problem.

Cheers!

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2003 BMW E53 4.4i Titansilber/Black
2008 BMW E90 328i manual
1972 BMW 2002 std Colorado Orange
2003 Audi TT 225 Coupe