So I think I have the assembly issue figured out. When I lightly tap the gas pedal assembly with my foot, I can hear a slight buzz. After I took out the assembly, tapped on the black box, and I could clearly hear the metallic rattle. I definitely think the rattle is from the spring used inside for the pedal motion, and the vibration we hear is traveling off the firewall to the dash. I did manage to put a foam "gasket" I made, and I'm not sure if it is thick enough to cancel the vibration but I think this is definitely a start. I didn't hear anything driving on the road but will give it a try on the freeway soon. Thank god for these forums!
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Originally Posted by Prog
The buzz/rattle is still gone for me. 
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Well that must be a huge improvement, and it must be nice to not hear that rattling anymore.