I too experienced the rattle sound from the right driver.
At first, I thought the right one was bad, so I flipped the headphone (left driver on my right ear, and vice versa), but strangely, I didn’t notice any rattle with the right driver on my left ear, and nor did the left one. I swapped back (left-left, right-right), and boom! Rattle did come back on the right driver.
I then swapped left-right cable from my cd-player to my amp, but I still experienced the rattle on the right no matter what channel being fed to the amp.
Before sending the phones back, I read this thread and decided to give it a try. I took out the cushion and found “nothing” on the driver –inside of my phone was very clean, except from some dust. Well, at that time I thought I really doomed, but something did catch my eyes –there were some hairs piercing halfway in the foam covering the driver
Even though they didn’t fully touch the driver, with some bass heavy passage, the driver might move far enough to touch them. Removing those hairs fixed the problem.
Ahh man! this should be included in the manual.